SGCO 2000

TK 50952-3.0

Printed ( Friday, January 03, 2003)

Copyright©2000 - Thermo King Corp. - Minneapolis, MN, U.S.A.

Printed (January 3, 2003)

Copyright © 2000 - Thermo King Corp. - Minneapolis, MN U.S.A.

Electronically printed in U.S.A.
General Information Assemblies and Subassemblies
When parts are indented in the description list, they are
Tables of Contents
preceded with a bullet ( • ). This indicates that the
This Parts Manual contains a numerical table of con- part(s) is available separately or included in an assem-
tents listing each assembly name, its associated Grid bly.
number and page number. The numerical table of con-
tents is arranged numerically by Grid number. There GRID NO. 67D6
are references in a parts list referring to other Grid num- SWITCH PANEL ASSEMBLY
bers, the numerical table of contents is arranged to facil- REF PART# DESCRIPTION QTY
itate finding the referenced illustrations. At the rear of
45-1239 PANEL - assy, switch 1
this parts manual are two indexes, a numerical and
alphabetical. The indexes contain all of the part num- 1 99-1960 • PANEL 1
bers and descriptions which appear in this manual. 99-6280 • • NAMEPLATE - panel 1
2 33-743 • GASKET 1

For example: the switch panel nameplate (99-6280) is

available separately, available as part of the switch
panel (99-1960) and with the panel assembly (45-1239).

ABBREVIATIONS The following abbreviations appear in parts manuals

A ac. . . . . . . . . . alternating
current
A/R . . . . . . . . as required
accum . . . . . . accumulator
adj . . . . . . . . . adjusting
al . . . . . . . . . . aluminum
alt. . . . . . . . . . alternator
amp . . . . . . . . ampere
assy . . . . . . . . assembly
B bd . . . . . . . . . board
brg . . . . . . . . . bearing
brkr . . . . . . . . breaker
brkt . . . . . . . . bracket
C C . . . . . . . . . . Celsius
cw . . . . . . . . . clockwise
ccw . . . . . . . . counter-
clockwise
cam . . . . . . . . camshaft
compr . . . . . . compressor
cond. . . . . . . . condenser
conn. . . . . . . . connecting,
connector
cyl . . . . . . . . . cylinder
D def . . . . . . . . . defrost
deg . . . . . . . . degree
dehyd. . . . . . . dehydrator
dia . . . . . . . . . diameter
dc. . . . . . . . . . direct current
disc . . . . . . . . discharge
diff . . . . . . . . . differential
E EMI . . . . . . . . Extended
. . . . . . . . . . . Maintenance
Interval
EEC . . . . . . . . European
Economic
Community
eng . . . . . . . . engine
E (continued) O os . . . . . . . . . . oversized
evap . . . . . . . . evaporator od . . . . . . . . . . outside diameter
exch . . . . . . . . exchanger
P pcb . . . . . . . . . printed circuit
exp . . . . . . . . . expansion
board
ext . . . . . . . . . external
pkg . . . . . . . . . package
F F. . . . . . . . . . . Farenheit ph . . . . . . . . . . phase
fill . . . . . . . . . . fillister pos . . . . . . . . . positive
fi . . . . . . . . . . . fuel injection psi . . . . . . . . . . pounds per
fl . . . . . . . . . . . flare square inch
fpt . . . . . . . . . . female pipe
R rad . . . . . . . . . radiator
thread
rcvr . . . . . . . . . receiver
ft . . . . . . . . . . . feet
ref . . . . . . . . . . reference
ftg . . . . . . . . . . fitting
reg . . . . . . . . . regulator
H hex . . . . . . . . . hexagon req . . . . . . . . . required
hh . . . . . . . . . . hexagon head rpm . . . . . . . . . revolutions per
hd . . . . . . . . . . head minute
hp . . . . . . . . . . horsepower
S sec . . . . . . . . . second
hsg . . . . . . . . . housing
sld . . . . . . . . . . solder
I id . . . . . . . . . . inside diameter soc hd . . . . . . . socket head
in . . . . . . . . . . inch (2.54 sol . . . . . . . . . . solenoid
centimeters) spl . . . . . . . . . . special
incl . . . . . . . . . includes sq . . . . . . . . . . square
inj . . . . . . . . . . injection ss . . . . . . . . . . stainless steel
int . . . . . . . . . . internal std. . . . . . . . . . standard
int th . . . . . . . . internal tooth stl . . . . . . . . . . steel
suct . . . . . . . . . suction
L liq . . . . . . . . . . liquid
sw . . . . . . . . . . switch
lg . . . . . . . . . . long
T term . . . . . . . . terminal
M mm . . . . . . . . . milimeter
temp . . . . . . . . temperature
mpt . . . . . . . . . male pipe thread
thk. . . . . . . . . . thick
mod . . . . . . . . modulating
U us . . . . . . . . . . undersize
N neg . . . . . . . . . negative
No. . . . . . . . . . number V vib . . . . . . . . . . vibrasorber
NS . . . . . . . . . not supplied
W w . . . . . . . . . . . watt
NSS . . . . . . . . not sold
w/ . . . . . . . . . . with
separately
w/o . . . . . . . . . without
SGCO 2000
Contents
Name Grid Page
SGCO 2000 REFERENCE SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . .5U93. . . . . . . . . . . . . . . . . . . . . .3
UNIT MOUNTING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105C8. . . . . . . . . . . . . . . . . . . .89
DEUTSCH IN-LINE CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . .112D9. . . . . . . . . . . . . . . . . . . .67
RECTIFIER GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119G2. . . . . . . . . . . . . . . . . . . .75
FUEL TANK GROUP (CGCO & SGCO) . . . . . . . . . . . . . . . . . . . . . . . .130G3. . . . . . . . . . . . . . . . . . . .43
EXCITER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131B4 . . . . . . . . . . . . . . . . . . . .71
RECTIFIER PLATE GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131B5 . . . . . . . . . . . . . . . . . . . .77
GEAR CASE GROUP (TK486/486E & TK482/482E) . . . . . . . . . . . . . .142C10. . . . . . . . . . . . . . . . . . . .7
FLYWHEEL HOUSING GROUP (TK486/486E & TK482/482E) . . . . . .142C11. . . . . . . . . . . . . . . . . . . .9
OIL SUMP GROUP (TK486/486E & TK482/482E) . . . . . . . . . . . . . . . .142C12. . . . . . . . . . . . . . . . . . .11
CYLINDER HEAD & VALVE COVER (TK486/486E & TK482/482E) . .142C13. . . . . . . . . . . . . . . . . . .13
CRANKSHAFT & PISTON GROUP (TK486/486E) . . . . . . . . . . . . . . . .142C14. . . . . . . . . . . . . . . . . . .17
INTAKE & EXHAUST MANIFOLD (TK486/486E & TK482/482E) . . . . .142F4 . . . . . . . . . . . . . . . . . . . .19
OIL FILTER & PUMP GROUP (TK486/486E & TK482/482E) . . . . . . . .142F6 . . . . . . . . . . . . . . . . . . . .23
FUEL PUMP ASSEMBLY (TK486/486E & TK482/482E) . . . . . . . . . . .142F8 . . . . . . . . . . . . . . . . . . . .27
FUEL INJECTION GROUP (TK486/486E) . . . . . . . . . . . . . . . . . . . . . .142F10 . . . . . . . . . . . . . . . . . . .31
FUEL INJECTION NOZZLE (TK486/486E) . . . . . . . . . . . . . . . . . . . . . .142F11 . . . . . . . . . . . . . . . . . . .33
STARTER ASSEMBLY (TK486/486E & TK482/482E) . . . . . . . . . . . . .142F12 . . . . . . . . . . . . . . . . . . .35
GASKET SET (TK486/486E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142F13 . . . . . . . . . . . . . . . . . . .37
NAMEPLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146G2. . . . . . . . . . . . . . . . . . . .91
CONTROL BOX COVER (mP-G) (SGCM, SGSM, SGCO) . . . . . . . . . .146G6. . . . . . . . . . . . . . . . . . . .63
CIRCUIT BOARD & RELAYS (mP-G) (SGCM, SGSM, SGCO) . . . . . .148G1. . . . . . . . . . . . . . . . . . . .61
WATER PUMP ASSEMBLY (TK486/486E & TK482/482E) . . . . . . . . .149C12. . . . . . . . . . . . . . . . . . .25
CYLINDER BLOCK GROUP (TK486E, Engines Manufactured 1/99
& After). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152D2. . . . . . . . . . . . . . . . . . . . .5
CAMSHAFT & DRIVE GEAR GROUP (TK486E, Engines
Manufactured 1/99 & After) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152D3. . . . . . . . . . . . . . . . . . . .21
FUEL INJECTION PUMP GROUP (TK486E, Engines Manufactured
1/99 & After). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152D4. . . . . . . . . . . . . . . . . . . .29
ALTERNATOR MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158B0 . . . . . . . . . . . . . . . . . . . .55
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158B8 . . . . . . . . . . . . . . . . . . . .49
MUFFLER GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158B9 . . . . . . . . . . . . . . . . . . . .47
BELTS, PULLEY & FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158C0. . . . . . . . . . . . . . . . . . . .53
CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158C1. . . . . . . . . . . . . . . . . . . .57
MAIN HARNESS ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158C2. . . . . . . . . . . . . . . . . . . .65
STRUCTURAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158C3. . . . . . . . . . . . . . . . . . . .83
STRUCTURAL COMPONENTS (REAR VIEW) . . . . . . . . . . . . . . . . . .158C5. . . . . . . . . . . . . . . . . . . .87
BATTERY & CABLE GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158C6. . . . . . . . . . . . . . . . . . . .81
FUEL FILTER & HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158C7. . . . . . . . . . . . . . . . . . . .41
OIL BASE GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158C8. . . . . . . . . . . . . . . . . . . .39
AIR CLEANER GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158D1. . . . . . . . . . . . . . . . . . . .45
ALTERNATOR GROUP (SGCO 2000, SGSM 2000, SGCM 2000) . . .166C8. . . . . . . . . . . . . . . . . . . .79
 5U93 SGCO 2000 REFERENCE SHEET
Revised
6/23/00

SGCO 2000 REF-

ERENCE SHEET
5U93
6/23/00

3
Revised
6/23/00 SGCO 2000 REFERENCE SHEET 5U93
B/M DESCRIPTION Date
062307 SGCO 2000 4/00
718201 SGCO 2000 4/00
062298 Battery 4/00
062312 Add Frame, Clip-On Header Pin Option 4/00
062246 Nameplates 4/00
062294 230V 4/00

4
 CYLINDER BLOCK GROUP (TK486E, Engines
152D2 Manufactured 1/99 & After)
Revised
11/27/01

CYLINDER BLOCK
GROUP (TK486E,
Engines Manufac-
tured 1/99 & After)
152D2
11/27/01

5
 CYLINDER BLOCK GROUP (TK486E, Engines
Revised
11/27/01 Manufactured 1/99 & After) 152D2
REF PART# DESCRIPTION QTY
101-317 ENGINE (TK486E, 12V) 1
101-318 ENGINE (TK486E, 24V) 1
101-330 ENGINE (TK486EH, 12V, 2600 rpm) 1
1 12-743 • BLOCK - cylinder 1
2 11-5499 • PLUG - frost (30 mm) 8
3 55-193 • PLUG - pipe (3/8) 1
4 55-6229 • PLUG 1
5 11-8914 • PLUG - frost (50 mm) 1
6 55-4600 • PLUG - pipe (1/4) 3
7 55-6177 • PLUG - pipe (1/8) 1
8 11-6555 • PLUG - frost (12 mm) 2
9 11-6680 • BUSHING - camshaft 1
10 11-8916 • BEARING - thrust (std) 2
11-8918 BEARING - thrust (.25 mm os) 2
11 11-8915 • BEARING - main 5
11-8917 • BEARING - main (.25 mm us) 5
12 NSS • CAP - bearing 4
13 55-885 • BOLT - bearing cap 10
14 55-5989 • PLUG (10 x 14 mm) 1
15 11-8919 LINER - service 4
16 41-2317 HEATER - frost plug 1

NOTE: This grid is for engines built after 1/99.

NOTE: Engines with serial numbers before EK00251 use radial seal 33-2759. Engines with serial numbers
EK00251 and after use axial oil seal 33-2974.

6
 142C10 GEAR CASE GROUP (TK486/486E & TK482/482E)
Revised
3/13/01

GEAR CASE
GROUP (TK486/
486E & TK482/
482E)
142C10
3/13/01

7
Revised
3/13/01 GEAR CASE GROUP (TK486/486E & TK482/482E) 142C10
REF PART# DESCRIPTION QTY
1 11-8920 CASE - gear 1
2 55-5784 • STUD - injection pump 3
3 55-5810 NUT 3
4 33-1953 O-RING - injection pump 1
5 203-348 GASKET - adhesive (RTV silicone) A/R
6 33-1910 O-RING 2
7 55-6234 PIN - dowel 2
8 55-5816 PIN - dowel 2
9 55-5768 SCREW - case 3
10 11-5091 CAP - oil fill 1
11 33-1954 O-RING - cap 1
12 11-8922 COVER - gear case 1
13 33-1952 • SEAL - oil 1
14 55-6367 • STUD - fuel pump 3
15 55-5809 SCREW - cover (45 mm) 7
16 55-6236 SCREW - cover (55 mm) 3
17 55-6188 SCREW - cover (20 mm) 1
18 55-4622 WASHER - sealing 5
19 11-8921 COVER - sound shield 1
20 33-2933 SPONGE 1
21 55-6237 SCREW - cover (85 mm) 6
22 55-5768 SCREW - cover (22 mm) 1
23 55-8854 SCREW - cover (12mm) 4
24 11-5082 COVER 1
25 33-1500 GASKET - cover 1
26 55-5768 SCREW - plug (see note) 1
27 204-1011 TOOL - injection pump gear remover 1

NOTE: Use screw 55-5768 for plugging the hole in the gear cover on engines with short oil line 11-8992.

8
 FLYWHEEL HOUSING GROUP (TK486/486E & TK482/
142C11 482E)
Revised
2/11/02

FLYWHEEL HOUS-
ING GROUP
(TK486/486E &
TK482/482E)
142C11
2/11/02

9
 FLYWHEEL HOUSING GROUP (TK486/486E & TK482/
Revised
2/11/02 482E) 142C11
REF PART# DESCRIPTION QTY
1 12-823 HOUSING - flywheel 1
2 11-6031 PLUG - access hole 1
3 55-8856 SCREW - housing (30 mm) 4
4 55-5794 SCREW - housing (25 mm) 6
5 55-8855 SCREW - plug (M12 x 16) 1
6 55-5816 PIN - dowel 2
7 11-8924 CASE - oil seal 1
8 33-2974 SEAL - oil (axial, see note) 1
33-2759 • SEAL - oil (radial, see note) 1
9 33-2969 GASKET - oil seal case 1
10 55-8857 SCREW - case (30 mm) 6
11 55-6191 SCREW - case (25 mm) 3
12 55-5816 PIN - dowel 2
13 204-952 TOOL - seal installer 1
14 204-994 TOOL - seal remover 1

NOTE: Engines with serial numbers before K00251 use radial seal 33-2759. Engines with serial numbers
K00251 and after use axial oil seal 33-2974.

10
 142C12 OIL SUMP GROUP (TK486/486E & TK482/482E)
Revised
7/23/02

OIL SUMP GROUP

(TK486/486E &
TK482/482E)
142C12
7/23/02

11
Revised
7/23/02 OIL SUMP GROUP (TK486/486E & TK482/482E) 142C12
REF PART# DESCRIPTION QTY
1 12-745 SUMP - oil (upper) 1
2 12-746 SUMP - oil (lower) 1
3 55-8437 PLUG - drain 2
4 203-348 GASKET - adhesive (RTV silicone) A/R
5 55-6246 SCREW - oil base (25 mm) 15
6 55-5809 SCREW - oil base (45 mm) 19
7 55-6237 SCREW - oil base (85 mm) 12
8 11-8667 DIPSTICK 1
9 33-1954 O-RING - dipstick 1
10 11-8923 CAP (units w/o oil level switch, push in type) 1
11 55-9167 ELBOW - hose 1
12 11-8984 HOSE - oil drain 1
13 55-5081 CAP - hose 1
14 91-4823 CLIP - hose 1
55-1587 SCREW - clip 1
55-2086 FLATWASHER 1
55-4953 NUT 1
15 41-402 SWITCH - oil level (push in type) 1
33-3060 • GASKET - switch 1
41-4470 SWITCH - oil level (threaded type) 1
16 91-7191 BRACKET - clip 1
17 11-9338 VALVE - oil drain 1
18 11-9448 FITTING - oil drain (ESOC) 1

12
 CYLINDER HEAD & VALVE COVER (TK486/486E &
142C13 TK482/482E)
Revised
3/8/02

CYLINDER HEAD &

VALVE COVER
(TK486/486E &
TK482/482E)
142C13
3/8/02

13
 CYLINDER HEAD & VALVE COVER (TK486/486E &
Revised
3/8/02 TK482/482E) 142C13
REF PART# DESCRIPTION QTY
1 11-8925 PIPE - breather 1
2 55-8442 • CLAMP - hose (24) 4
3 11-8994 • ORIFICE - breather 1
4 11-8941 COVER - valve 1
5 33-2935 • GASKET - valve cover 1
6 11-5103 • KNOB - valve cover 3
7 33-3512 • O-RING - cover 3
8 11-6693 • COVER - breather 1
9 11-8672 • PLATE - screen 1
10 33-2762 • O-RING 1
11 11-8671 • BAFFLE - breather 1
12 55-5768 • SCREW - cover 2
11-8938 SHAFT - rocker arm 1
13 11-8939 • SHAFT - rocker arm 1
14 11-6702 • SUPPORT - rocker arm 2
15 11-6703 • SUPPORT - rocker arm 3
16 55-6245 • STUD - valve cover 3
17 11-6704 • SPRING 4
18 11-8940 • ARM - rocker 8
19 55-8859 •• SCREW - valve adjust 8
20 55-8860 •• NUT 8
21 55-6193 SCREW - support (50 mm) 7
22 55-6246 SCREW - support (25 mm) 3
23 12-747 HEAD - cylinder 1
24 11-6708 • RETAINER - nozzle 4
25 11-8937 • PROTECTOR - nozzle 4
26 11-6707 • SEAT - nozzle 4
27 55-5138 • STUD - nozzle retainer 8
28 55-5792 • NUT 8
29 11-6567 • PLUG - frost (40 mm) 1
30 55-5803 • PIN - spring 2
31 11-8930 • VALVE - intake 4
32 11-8926 • SEAT - valve (intake) 4
33 11-8928 • GUIDE - valve (intake) 4
34 11-8935 • SEAL - valve stem (intake) 4
35 11-8931 • VALVE - exhaust 4
36 11-8927 • SEAT - valve (exhaust) 4
37 11-8929 • GUIDE - valve (exhaust) 4

14
 CYLINDER HEAD & VALVE COVER (TK486/486E &
142C13 TK482/482E)
Revised
3/8/02

15
 CYLINDER HEAD & VALVE COVER (TK486/486E &
Revised
3/8/02 TK482/482E) 142C13
REF PART# DESCRIPTION QTY
38 11-8934 • SEAL - valve stem (exhaust) 4
39 11-8932 • SPRING - valve 8
40 11-8933 • RETAINER - spring 8
41 55-8858 • KEEPER - valve 8
42 11-8936 • CAP - valve 8
43 11-6698 LIFTER - engine 2
44 55-5801 SCREW - lifter 4
45 11-8942 FLANGE 1
46 55-5763 • PLUG 1
47 33-2934 GASKET - flange 1
48 55-5768 SCREW - flange 4
49 33-2932 GASKET - cylinder head 1
50 55-8853 STUD - cylinder head 18
51 91-3542 TUBE - sponge (insulation, cut to 11.0 in lg) 1

16
 142C14 CRANKSHAFT & PISTON GROUP (TK486/486E)
Revised
12/10/01

CRANKSHAFT &
PISTON GROUP
(TK486/486E)
142C14
12/10/01

17
Revised
12/10/01 CRANKSHAFT & PISTON GROUP (TK486/486E) 142C14
REF PART# DESCRIPTION QTY
1 11-8948 PISTON (std, incl 2-4) 4
11-8955 PISTON (w/ ring, .25 os) 4
11-8958 PISTON (w/ ring, .50 os) 4
2 11-8949 RING SET (std) 2
11-8956 RING SET (.25 os) 4
11-8959 RING SET (.50 os) 4
3 11-8950 PIN - piston 4
4 11-8951 CIRCLIP 8
5 11-8952 ROD - connecting 4
6 11-8953 BUSHING - piston pin 4
7 11-8954 BEARING - connecting rod (std) 4
11-8957 BEARING - connecting rod (.25 us) 4
8 55-8865 BOLT - connecting rod 8
9 12-750 FLYWHEEL 1
10 11-8947 • GEAR - ring 1
11 55-8864 BOLT - flywheel 6
12 55-5816 PIN - dowel 1
13 12-749 CRANKSHAFT 1
14 11-6719 • KEY - gear 1
15 11-6724 GEAR - crankshaft 1
16 55-5834 PIN - spring 1
17 77-2673 PULLEY - crankshaft 1
18 55-6249 WASHER 1
19 55-6250 BOLT - v-pulley 1

18
 INTAKE & EXHAUST MANIFOLD (TK486/486E &
142F4 TK482/482E)
Revised
12/28/99

INTAKE &
EXHAUST MANI-
FOLD (TK486/486E
& TK482/482E)
142F4
12/28/99

19
 INTAKE & EXHAUST MANIFOLD (TK486/486E &
Revised
12/28/99 TK482/482E) 142F4
REF PART# DESCRIPTION QTY
1 33-2936 GASKET - intake manifold 1
2 11-8943 MANIFOLD - intake 1
3 55-5763 • PLUG 1
4 55-8861 • JOINT - breather 1
5 55-6188 SCREW - intake manifold (20 mm) 6
6 55-8717 SCREW - intake manifold (80 mm) 1
7 11-8673 INLET - intake manifold 1
8 33-2764 GASKET - inlet 1
9 41-2147 HEATER - air 1
10 33-2765 GASKET - air heater 1
11 55-6236 SCREW - inlet (55 mm) 4
12 11-8944 MANIFOLD - exhaust 1
13 33-2937 GASKET - exhaust manifold 1
14 55-8862 STUD - exhaust manifold 2
15 55-5791 NUT 2
16 55-5772 SCREW - exhaust manifold (40 mm) 7

20
 CAMSHAFT & DRIVE GEAR GROUP (TK486E,
152D3 Engines Manufactured 1/99 & After)
Revised
1/10/00

CAMSHAFT &
DRIVE GEAR
GROUP (TK486E,
Engines Manufac-
tured 1/99 & After)
152D3
1/10/00

21
 CAMSHAFT & DRIVE GEAR GROUP (TK486E,
Revised
1/10/00 Engines Manufactured 1/99 & After) 152D3
REF PART# DESCRIPTION QTY
1 11-9261 CAMSHAFT 1
2 11-6719 KEY - gear 1
3 11-6681 BEARING - thrust 1
4 55-5768 BOLT - plate 2
5 11-6716 GEAR - camshaft 1
6 11-6717 TAPPET 8
7 11-8945 ROD - push 8
8 11-9248 SHAFT - idler gear 1
9 11-6722 • BUSHING - idler gear 1
10 11-6721 GEAR (w/ bushing) 1
11 11-8993 NOZZLE - oil 1
12 55-8967 SCREW - nozzle 2
13 55-5809 SCREW - gear 2
14 101-321 PUMP - fuel injection (see 149F9) 1
15 11-9202 GEAR - pump 1
16 11-9203 CAM - feed pump 1
17 55-8863 WASHER 1
18 55-6254 NUT 1

NOTE: This grid is for engines built after 1/99. Engines built after 1/99 have a serial number beginning with an
"L".

22
 OIL FILTER & PUMP GROUP (TK486/486E & TK482/
142F6 482E)
Revised
11/27/01

OIL FILTER &

PUMP GROUP
(TK486/486E &
TK482/482E)
142F6
11/27/01

23
 OIL FILTER & PUMP GROUP (TK486/486E & TK482/
Revised
11/27/01 482E) 142F6
REF PART# DESCRIPTION QTY
1 11-8668 PIPE - oil (engines before 6/96, TK486 S/N L00261, TK482 S/ 1
N A00261)
2 11-8992 • PIPE - oil (engines 6/96 & after, Serial No. 00261) 1
3 55-4644 BOLT - eye 1
4 55-4733 SEAL - washer (10) 2
5 55-4645 BOLT - eye 2
6 55-4622 WASHER - sealing (8) 4
7 55-5768 SCREW - plug 1
8 55-6177 PLUG 1
9 11-8962 BRACKET - filter (engines before TK486 S/N L32014 & 1
TK482 S/N A08750 use w/ oil filter 11-7382)
10 11-8964 • ORIFICE 1
11 55-8867 • BUSHING 1
12 55-5763 • PLUG 2
11-8995 • VALVE - check (assembly) 1
13 55-8868 •• BALL 1
14 11-8965 •• SPRING 1
15 33-2970 •• GASKET 1
16 11-8963 • RETAINER 1
17 33-2931 GASKET - bracket 1
18 55-6188 SCREW - bracket (20 mm) 1
19 55-5809 SCREW - bracket 1
20 55-8869 SCREW - bracket (75 mm) 1
21 11-7382 FILTER - oil 1
22 11-8961 PIPE - oil pickup 1
23 33-2938 GASKET - pipe 1
24 55-6191 SCREW - pipe (35 mm) 2
25 11-9249 PUMP - oil 1
26 11-9250 GASKET - oil pump 1
27 55-6251 SCREW - oil pump (25 mm) 4
28 11-9354 BRACKET - filter (incl 10-16, eng after TK486 S/N L32014 & 1
TK482 S/N A08750 use w/ fitler 11-9182)
29 11-9182 FILTER - oil (EMI 3000) 1
30 11-9447 FITTING - oil inlet (ESOC) 1

24
 WATER PUMP ASSEMBLY (TK486/486E & TK482/
149C12 482E)
Revised
10/30/02

WATER PUMP
ASSEMBLY
(TK486/486E &
TK482/482E)
149C12
10/30/02

25
 WATER PUMP ASSEMBLY (TK486/486E & TK482/
Revised
10/30/02 482E) 149C12
REF PART# DESCRIPTION QTY
1 11-9499 PUMP - water (ELC compatible, low mount, current style) 1
2 55-8443 • PLUG 1
3 33-3096 • GASKET - water pump 1
4 33-2768 GASKET 1
5 11-9589 THERMOSTAT 1
6 33-2767 GASKET 1
7 11-8675 COVER - thermostat 1
8 55-6188 SCREW - thermostat 2
9 55-6248 SCREW - pump 3
10 77-1426 PULLEY - water pump 1
11 77-1427 SHIM - pulley 4
12 77-1428 SPACER 1
13 55-5792 NUT 4
14 11-8996 JOINT - pump 1
15 33-3097 GASKET - joint 1
16 33-3098 O-RING - joint 1
17 55-5768 SCREW - joint 3
18 55-5780 DRAIN COCK 1
19 33-1745 WASHER - sealing 1
20 11-9256 PLUG 1

26
 142F8 FUEL PUMP ASSEMBLY (TK486/486E & TK482/482E)
Revised
9/7/00

FUEL PUMP
ASSEMBLY
(TK486/486E &
TK482/482E)
142F8
9/7/00

27
Revised
9/7/00 FUEL PUMP ASSEMBLY (TK486/486E & TK482/482E) 142F8
REF PART# DESCRIPTION QTY
1 11-7433 PUMP - fuel 1
2 11-8970 • PISTON 1
3 11-8971 • SPRING - piston 1
4 55-8871 • RETAINER 1
5 33-2940 • GASKET 1
6 11-8998 • TAPPET 1
7 55-8872 • PIN - snap 1
8 11-8972 • VALVE 2
9 11-8973 • SPRING 2
10 11-8974 • RETAINER - valve 1
11 33-2941 • O-RING 1
12 11-8680 • PUMP 1
13 11-8975 • ADAPTER 1
14 33-2771 • O-RING 1
15 11-8976 • JOINT - pipe 1
16 11-8977 • GASKET 2
17 11-7499 • JOINT - pipe 1
18 11-8681 • JOINT - pipe 1
19 33-1749 • GASKET 4
20 11-7707 • JOINT - pipe 1
21 11-8682 • JOINT - pipe 1
22 33-2942 O-RING 1
23 55-4750 NUT 3
24 55-6367 STUD - fuel pump 3

28
 FUEL INJECTION PUMP GROUP (TK486E, Engines
152D4 Manufactured 1/99 & After)
Revised
10/16/02

FUEL INJECTION
PUMP GROUP
(TK486E, Engines
Manufactured 1/99
& After)
152D4
10/16/02

29
 FUEL INJECTION PUMP GROUP (TK486E, Engines
Revised
10/16/02 Manufactured 1/99 & After) 152D4
REF PART# DESCRIPTION QTY
1 101-321 PUMP - fuel injection 1
101-331 PUMP - fuel injection (TK486EH, 2600 rpm engine) 1
2 33-1953 O-RING - injection pump 1
3 55-5784 STUD - injection pump 3
4 55-5810 NUT 3
5 11-6125 RETAINER - shaft 1
6 55-5822 SCREW - retainer 1
7 11-9562 LEVER - control 1
8 55-5810 NUT 1
9 41-4306 SOLENOID - stop (12V) 1
41-2444 SOLENOID - stop (24V) 1
10 33-2230 O-RING - solenoid 1
11 55-8448 SCREW - solenoid 2
12 55-8870 BOLT - fuel control 1
13 55-8620 WASHER 2
14 55-4615 NUT 1
15 55-4670 NUT - cap 1
16 11-5170 SEAL - lead 1
11-9205 SEAL - lead 1
17 204-1083 TOOL - plunger spring support plate 1
30-267 KIT - gasket (injection pump) 1
18 33-3204 • GASKET - side cover 1
19 11-9613 • COVER - side 1
20 51-269 • SCREW - cover 11
21 33-3689 • GASKET - bottom cover 1
22 11-9612 • COVER - bottom 1
23 33-1970 • O-RING - screw 1
24 33-3690 • SEAL - washer 1
25 33-1753 • O-RING - tappet 4
26 33-1530 • O-RING - delivery 4
27 33-1973 • O-RING - deflector check 1

NOTE: This grid is for engines built after 1/99. Engines built after 1/99 have a serial number beginning with an
"L".

30
 142F10 FUEL INJECTION GROUP (TK486/486E)
Revised
9/27/02

FUEL INJECTION
GROUP (TK486/
486E)
142F10
9/27/02

31
Revised
9/27/02 FUEL INJECTION GROUP (TK486/486E) 142F10
REF PART# DESCRIPTION QTY
1 11-6791 SCREW - banjo 1
2 11-8979 BANJO - fuel inlet 1
3 55-8620 GASKET 2
4 11-8823 RETAINER 3
5 55-8626 SCREW - retainer 3
6 11-8728 PIPE - fuel injection 1
7 11-8729 PIPE - fuel injection 1
8 11-8730 PIPE - fuel injection 1
9 11-8731 PIPE - fuel injection 1
10 11-8715 VALVE - fuel injection (see 142F11) 4
11 11-9617 CAP 1
12 55-6195 CLAMP 9
13 11-6794 PIPE - fuel return 3
14 11-6793 PIPE - fuel return 1
15 11-8997 BANJO - fuel return 1
16 11-6797 VALVE - check (before 1/00) 1
17 33-1975 GASKET 2
18 11-6110 BOLT - air bleed (1/00 & after) 1
19 204-1056 ADAPTER - compression tester 1
11-9446 • VALVE - Schrader 1
55-1819 • SEAL - copper 1
55-4607 • WASHER 2
204-542 TESTER - compression 1

32
 142F11 FUEL INJECTION NOZZLE (TK486/486E)
Revised
12/29/99

FUEL INJECTION
NOZZLE (TK486/
486E)
142F11
12/29/99

33
Revised
12/29/99 FUEL INJECTION NOZZLE (TK486/486E) 142F11
REF PART# DESCRIPTION QTY
11-8715 VALVE - fuel injection 4
1 11-6787 • HOLDER - nozzle 1
2 11-6108 • SHIM SET 1
3 11-6788 • SPRING - nozzle 1
4 11-6106 • SEAT - nozzle spring 1
5 11-6789 • PLATE - stop 1
6 11-6790 • PIN 1
7 11-8978 • NOZZLE 1
8 11-6786 • NUT - nozzle case 1

34
 142F12 STARTER ASSEMBLY (TK486/486E & TK482/482E)
Revised
12/28/99

STARTER ASSEM-
BLY (TK486/486E &
TK482/482E)
142F12
12/28/99

35
Revised
12/28/99 STARTER ASSEMBLY (TK486/486E & TK482/482E) 142F12
REF PART# DESCRIPTION QTY
45-1688 STARTER (12V) 1
45-1823 STARTER (24V) 1
1 41-2149 • ARMATURE 1
2 77-2468 • BEARING 1
3 77-2469 • BEARING 1
4 NSS • YOKE - assembly 1
5 41-2150 • COIL - field 1
55-8894 •• SCREW - field coil 4
6 41-2151 •• BRUSH 2
7 91-8112 • COVER - rear 1
8 41-2152 • HOLDER - brush 1
9 41-2153 •• SPRING - brush 4
10 41-2151 •• BRUSH 2
11 55-8897 • SCREW - cover 2
12 55-8895 • BOLT - thru 2
13 41-2162 • SWITCH - thermo (early units) 1
14 55-790 •• LOCKWASHER 1
15 41-2154 • PINION - assembly 1
16 41-2155 •• CLUTCH - assembly 1
17 77-2470 •• BEARING - ball 1
18 77-2471 •• BEARING - ball 1
19 41-2156 •• STOPPER - pinion 1
20 41-2161 • RETAINER 1
21 55-8896 • SCREW - retainer 3
22 41-2160 • HOUSING - gear 1
23 41-2158 • SOLENOID (12V) 1
41-2444 • SOLENOID (24V) 1
24 41-2157 • LEVER 1
25 41-2159 • COVER - dust 1
26 55-5770 • SCREW - solenoid 2
27 55-8898 SCREW - starter 2

36
 142F13 GASKET SET (TK486/486E)
Revised
12/10/01

GASKET SET
(TK486/486E)
142F13
12/10/01

37
Revised
12/10/01 GASKET SET (TK486/486E) 142F13
REF PART# DESCRIPTION QTY
30-248 KIT - gasket set 1
1 33-2932 • GASKET - cylinder head 1
2 33-1500 • GASKET 1
3 33-1953 • O-RING - fuel injection pump 1
4 11-8935 • SEAL - valve stem (exhaust) 4
11-8934 • SEAL - valve stem (intake) 4
5 11-8937 • PROTECTOR - nozzle 4
6 11-6707 • SEAT - nozzle 4
7 33-2935 • GASKET - valve cover 1
8 33-2764 • GASKET 1
9 33-2936 • GASKET - intake manifold 1
10 33-2937 • GASKET - exhaust manifold 1
11 11-9250 • GASKET - oil pump 1
12 33-2938 • GASKET 1
13 33-2931 • GASKET 1
14 33-3096 • GASKET - water pump (low mount) 1
33-3259 • GASKET - water pump (high mount) 1
15 33-3097 • GASKET - thermostat case 1
16 33-2767 • GASKET 1
17 33-2768 • GASKET 1
18 33-2765 • GASKET - air heater 1
19 33-2934 • GASKET - flange 1
20 55-4733 • GASKET - round (10) 2
55-8620 • GASKET (12) 2
33-1975 • GASKET (12, round) 2
55-4622 • WASHER - sealing (8) 9
21 33-3512 • O-RING (12.0) 3
33-1910 • O-RING (16.0) 2
33-2942 • O-RING (31.5) 1
33-1954 • O-RING (32.0) 3
33-2762 • O-RING (50.0) 1
22 33-2969 • GASKET - oil seal case 1
23 33-1531 • GASKET - eye bolt 2
24 33-3098 • O-RING - water pump (low mount) 1
33-3263 • O-RING - water pump (high mount) 1
25 33-2974 • SEAL - oil (rear, axial) 1
26 33-1952 • SEAL - oil (front) 1
27 203-348 GASKET - adhesive (RTV silicone) A/R
38
 158C8 OIL BASE GROUP
Revised
5/16/01

OIL BASE GROUP

158C8
5/16/01

39
Revised
5/16/01 OIL BASE GROUP 158C8
REF PART# DESCRIPTION QTY
1 41-402 SWITCH - oil level 1
33-3060 • GASKET - switch 1
2 55-3744 ELBOW - hose 1
3 11-6829 HOSE - oil drain (16.50 in) 1
4 92-258 CLIP - hose 1
55-1587 SCREW - clip 1
55-2086 FLATWASHER 1
55-4953 NUT 1
5 55-5081 CAP - drain hose 1
6 10-242 KIT - sleeve & eyelet 1
7 11-4941 NUT - hose (3/8) 2
8 11-4372 HOSE (3/8) 1
9 55-4515 FITTING - hose (3/8) 2
10 55-8665 ELBOW - oil pressure switch 1
11 44-8883 SENSOR - oil pressure 1
12 55-3031 SCREW - elbow 2
13 55-2001 FLATWASHER 2
14 55-7616 WASHER - insulating 2
55-7062 INSERT 2
15 33-2458 MAT - insulating 1
16 55-2964 LOCKWASHER 2
17 55-2998 LOCKWASHER (internal tooth) 1
18 55-3013 FLATWASHER 1
19 55-3513 SCREW - terminal 1
20 91-8677 BRACKET - oil sensor 1
21 55-229 TEE - oil pressure switch 1
22 41-385 SWITCH - oil pressure 1
23 11-7382 FILTER - oil (dual element) 1
11-9182 FILTER - oil (EMI 3000) 1
24 44-9298 SENSOR - rpm 1

40
 158C7 FUEL FILTER & HOSES
Revised
2/5/01

FUEL FILTER &

HOSES
158C7
2/5/01

41
Revised
2/5/01 FUEL FILTER & HOSES 158C7
REF PART# DESCRIPTION QTY
1 11-9015 BASE - fuel filter 1
55-3490 SCREW - base 2
55-4954 NUT - base 2
55-2958 FLATWASHER 2
2 11-8047 FILTER - fuel 1
11-9342 FILTER - fuel (EMI 3000) 1
3 11-9016 SHAFT - water bleed 1
4 11-9017 SPUD - filter 1
203-393 SEALER - Loctite A/R
5 11-5320 ELBOW (1/4) 3
6 10-243 KIT - sleeve & eyelet (1/4) 5
7 11-4841 NUT (1/4) 4
8 11-4367 HOSE (1/4 od x 35 ft lg) A/R
9 10-242 KIT - sleeve & eyelet (3/8) 4
10 11-4941 NUT (3/8) 3
11 11-4372 HOSE (3/8 od x 35 ft lg) A/R
12 55-4203 CLAMP - hose 2
55-5022 SCREW - clamp 2
55-2958 FLATWASHER 2
55-2959 LOCKWASHER 2
13 11-4380 ELBOW (3/8) 1
14 101-321 PUMP - injection (see 152D4) 1
15 11-7433 PUMP - fuel (see 142F8) 1

42
 130G3 FUEL TANK GROUP (CGCO & SGCO)
Revised
12/5/02

FUEL TANK
GROUP (CGCO &
SGCO)
130G3
12/5/02

43
Revised
12/5/02 FUEL TANK GROUP (CGCO & SGCO) 130G3
REF PART# DESCRIPTION QTY
1 NSS TANK - fuel (see 158C3) 1
2 55-5617 VENT 2
3 11-8719 PLUG - fuse 2
4 11-8048 CAP - fuel tank 2
5 11-4372 HOSE (3/8 od x 35 ft lg) A/R
6 11-4941 NUT - hose fitting (3/8) 2
7 10-242 KIT - sleeve & eyelet (3/8) 2
8 11-4959 ELBOW (3/8) 2
9 11-8718 GAUGE - fuel 2
10 11-8887 TUBE - fuel feed 2
11 11-8653 BALL - check 1
12 55-3364 PLUG - pipe 1

44
 158D1 AIR CLEANER GROUP
Revised
6/23/00

AIR CLEANER
GROUP
158D1
6/23/00

45
Revised
6/23/00 AIR CLEANER GROUP 158D1
REF PART# DESCRIPTION QTY
1 11-3733 CLEANER - air 1
2 99-1400 • CLAMP - oil cup 1
3 11-2610 • CUP - air cleaner 1
4 11-2457 CLAMP 1
5 55-8116 • SCREW - clamp 1
6 55-3472 • NUT 1
55-2969 SCREW - clamp 2
55-2958 FLATWASHER 4
55-4954 NUT 2
7 91-8744 CLAMP - air cleaner 1
55-4955 NUT - clamp 2
8 91-8678 BRACKET - clamp 1
55-2969 SCREW - bracket 2
55-2958 FLATWASHER 4
55-4954 NUT 2
9 55-3991 CLAMP - hose 2
10 11-9289 HOSE - air 1
10-317 KIT - adapter & hose 1
11 11-8858 • ADAPTER - air intake 1
12 33-2854 • O-RING 1
13 91-7555 • SPACER 2
14 11-8900 • HOSE - breather 1
15 11-8901 • HOSE - insulation 1
16 55-1592 • CONNECTOR - hose 1
55-5022 SCREW - adapter 2
55-4613 FLATWASHER 2
55-2959 LOCKWASHER 2
17 55-2332 BANDWRAP 2

46
 158B9 MUFFLER GROUP
Revised
6/23/00

MUFFLER GROUP
158B9
6/23/00

47
Revised
6/23/00 MUFFLER GROUP 158B9
REF PART# DESCRIPTION QTY
1 12-800 MUFFLER 1
2 33-2314 GASKET - muffler 1
3 55-3089 SCREW - muffler 2
4 55-2958 FLATWASHER 4
5 55-2959 LOCKWASHER 2
6 55-2114 NUT 2
7 55-5022 SCREW - muffler 2
8 55-790 LOCKWASHER 2
9 91-7234 U-BOLT 2
10 91-7233 SADDLE - u-bolt 2
11 55-2086 FLATWASHER 4
55-1800 LOCKWASHER 4
55-3472 LOCKNUT 4
12 11-9286 TUBE - exhaust 1
13 92-256 BRACKET - exhaust tube 1
55-2977 SCREW - bracket 2
55-2086 FLATWASHER 4
55-4953 LOCKNUT 2

48
 158B8 ENGINE COOLING SYSTEM
Revised
5/22/02

ENGINE COOLING
SYSTEM
158B8
5/22/02

49
Revised
5/22/02 ENGINE COOLING SYSTEM 158B8
REF PART# DESCRIPTION QTY
1 12-799 RADIATOR 1
55-8752 • INSERT 6
55-3018 SCREW - radiator 6
55-2086 FLATWASHER 12
55-1800 LOCKWASHER 6
2 11-8913 CAP - radiator 1
3 55-9011 DRAIN COCK - radiator 1
4 91-8036 BRACKET - radiator (top) 1
55-2979 SCREW - bracket 7
55-2086 FLATWASHER 14
55-4953 NUT 7
5 92-1350 SCREEN - radiator 1
6 91-8035 ANGLE - radiator (front) 1
55-2957 SCREW - angle 5
55-2979 SCREW 2
55-2086 FLATWASHER 14
55-4953 NUT 7
7 98-5711 SHROUD - radiator 1
55-3018 SCREW - shroud 6
55-2086 FLATWASHER 6
55-1800 LOCKWASHER 6
8 98-5723 ORIFICE - radiator 1
55-3018 SCREW - orifice 6
55-3045 WASHER - dome 6
9 11-9287 HOSE - water pump to radiator (silicone) 1
10 11-9288 HOSE - radiator to engine (silicone) 1
11 55-5400 CLAMP - hose 4
12 11-4693 HANGER - overflow tank 1
55-2977 SCREW - hanger 2
55-2086 FLATWASHER 2
55-6526 INSERT 2
13 99-8301 CAP & CHAIN - overflow tank 1
14 11-4607 TANK - overflow 1
15 99-1655 HOSE - overflow 1
55-2796 CLAMP - hose 4
16 41-2330 SWITCH - water temperature 1
55-5023 BUSHING 1
17 55-2554 PLUG - pipe 1
18 55-5090 TEE - pipe 1
19 55-9091 ELBOW - pipe 1
20 11-9499 PUMP - water (ELC compatible, see 149C12) 1
21 12-633 HOSE - water pump 1

50
158B8 ENGINE COOLING SYSTEM
Revised
5/22/02

51
Revised
5/22/02 ENGINE COOLING SYSTEM 158B8
REF PART# DESCRIPTION QTY
22 55-6731 CLAMP - hose 2
23 91-7217 BRACKET - overflow tank 1
55-2977 SCREW - bracket 4
55-2086 FLATWASHER 8
55-4953 LOCKNUT 4
24 91-7782 PAD - radiator 1
25 11-8888 TANK - expansion 1
55-3021 SCREW - tank 4
55-2086 FLATWASHER 4
55-1800 LOCKWASHER 4
26 55-5400 CLAMP - hose 2
27 11-8891 HOSE - outlet 1
28 91-7497 COVER - access 1
55-2955 SCREW - cover 2
29 41-1818 SENSOR - water level 1

52
 158C0 BELTS, PULLEY & FAN
Revised
12/10/01

BELTS, PULLEY &

FAN
158C0
12/10/01

53
Revised
12/10/01 BELTS, PULLEY & FAN 158C0
REF PART# DESCRIPTION QTY
1 78-1108 BELT - fan & water pump 1
2 77-2673 PULLEY - crankshaft (see 142C14) 1
3 92-248 SPACER - fan 1
4 78-618 FAN - radiator 1
5 55-7660 SCREW - fan (CGCO & SGCO) 3
55-6764 SCREW - fan (CGSM, SGSM, CGCM & SGCM) 3
6 55-2959 LOCKWASHER 3
7 77-1345 PULLEY - water pump (see 149C12) 1
8 204-427 GAUGE - belt tension 1

NOTE: Crankshaft pulley belt adjustment.

54
 158B0 ALTERNATOR MOUNTING
Revised
5/3/01

ALTERNATOR
MOUNTING
158B0
5/3/01

55
Revised
5/3/01 ALTERNATOR MOUNTING 158B0
REF PART# DESCRIPTION QTY
1 92-226 BRACKET - generator, rear 1
55-3304 SCREW - bracket 4
55-2958 FLATWASHER 4
55-2959 LOCKWASHER 4
2 55-2557 SCREW - frame 2
3 55-2038 FLATWASHER 2
4 55-3595 WASHER - special 4
5 55-4952 NUT 4
6 99-3649 MOUNT - vibration 2
7 92-224 BRACKET - generator, bottom 1
55-8137 SCREW - bracket, generator 6
55-6988 FLATWASHER 6
55-7066 LOCKWASHER 6
8 55-6814 STUD - power pack 6
9 55-3512 WASHER - special 12
10 99-1433 MOUNT - vibration 6
11 99-1916 MOUNT - vibration 6
12 99-1642 SPACER 6
13 55-5205 NUT 6
14 92-225 BRACKET - engine 1
15 92-228 BRACKET - engine (front) 1
16 92-229 BRACKET - engine (front) 1
55-7412 SCREW - bracket, engine 8
55-7000 LOCKWASHER 8
55-6999 FLATWASHER 4
17 44-9298 SENSOR - rpm 1

56
 158C1 CONTROL BOX
Revised
6/23/00

CONTROL BOX
158C1
6/23/00

57
Revised
6/23/00 CONTROL BOX 158C1
REF PART# DESCRIPTION QTY
1 92-255 BOX - control 1
55-2977 SCREW - box 4
55-1800 LOCKWASHER 4
55-2086 FLATWASHER 4
2 55-2965 NUT - ground 2
55-2964 LOCKWASHER 1
55-2001 FLATWASHER 1
55-2996 LOCKWASHER (internal tooth) 2
3 44-3345 REGULATOR - voltage 1
55-2955 SCREW - regulator 3
55-2964 LOCKWASHER 3
55-2001 FLATWASHER 3
4 41-1418 PLUG (12 contact, 10 amp) 1
5 44-5555 BOARD - terminal (3 terminal, 55 amp) 1
6 44-9282 BOARD - terminal (6 terminal, 55 amp) 1
55-2990 NUT - terminal board 4
55-2202 LOCKWASHER 4
55-2201 FLATWASHER 4
7 99-3855 MARKSTRIP 1
8 91-860 MARKSTRIP 1
9 45-1719 EXCITER (see 131B4) 1
55-4953 NUT - exciter 4
55-2086 FLATWASHER 4
10 41-3614 HARNESS - main (see 146G4) 1
11 44-5030 • CONNECTOR (6 pin, female) 1
12 44-5622 • CONNECTOR (6 pin, female) 2
13 44-5719 • CONNECTOR (8 pin, female) 1
14 44-5814 • CONNECTOR (4 pin, female) 1
15 55-3539 CONNECTOR - barb 1
16 33-1056 O-RING 1
17 55-2636 LOCKNUT 1
18 Not Used
19 NSS COVER - mP-G (see 146G6) 1
55-2979 SCREW - cover 4
55-1800 LOCKWASHER 4
55-2086 FLATWASHER 4
55-3059 NUT - captive 4
20 91-6841 BRACKET - plug support 1
21 33-3167 GASKET - receptacle (230V) 1
33-3168 GASKET - receptacle (460V) 1
22 41-3403 RECEPTACLE (230V) 1
41-3404 RECEPTACLE (460V) 1

58
158C1 CONTROL BOX
Revised
6/23/00

59
Revised
6/23/00 CONTROL BOX 158C1
REF PART# DESCRIPTION QTY
23 98-5035 HOSE - main harness 1
24 41-2191 BOARD - pc timer (fuel) 1
55-3099 SCREW - board 2
55-2996 LOCKWASHER 4
55-8430 SPACER - pc board 1
55-9400 WASHER - shoulder 2
25 41-893 RELAY - mini 1
26 91-1277 RETAINER - harness 1
55-2262 RIVET - retainer 1

60
 CIRCUIT BOARD & RELAYS (mP-G) (SGCM, SGSM,
148G1 SGCO)
Revised
2/21/01

CIRCUIT BOARD &

RELAYS (mP-G)
(SGCM, SGSM,
SGCO)
148G1
2/21/01

61
 CIRCUIT BOARD & RELAYS (mP-G) (SGCM, SGSM,
Revised
2/21/01 SGCO) 148G1
REF PART# DESCRIPTION QTY
1 45-1797 CONTROLLER - mP-G (see 146G6) 1
2 N/A BRACKET - relay board (has been replaced with item 3) 1
3 91-8920 BRACKET - relay board 1
55-3000 SCREW - bracket 4
55-2996 LOCKWASHER 4
55-2001 FLATWASHER 4
4 41-2906 BOARD - relay (mP-G) 1
5 91-1277 • RETAINER - harness connector 8
55-2262 • RIVET - retainer 8
55-3550 • FLATWASHER 8
6 41-895 • RELAY 4
7 44-8244 FUSE LINK 1
55-346 NUT - jumper & link 6
55-1852 LOCKWASHER 9
55-401 FLATWASHER 3
8 44-1458 JUMPER 1
9 41-2530 HARNESS - voltmeter 1
10 44-5622 • CONNECTOR (6 pin) 1
11 41-2586 CABLE - ribbon 1
12 55-9127 SPACER - pc board 2
13 41-2585 BOARD - printed circuit, interconnecting 1
55-5279 SCREW - pc board 2
55-2998 LOCKWASHER 2
55-3013 FLATWASHER 2

62
 CONTROL BOX COVER (mP-G) (SGCM, SGSM,
146G6 SGCO)
Revised
12/5/02

CONTROL BOX
COVER (mP-G)
(SGCM, SGSM,
SGCO)
146G6
12/5/02

63
 CONTROL BOX COVER (mP-G) (SGCM, SGSM,
Revised
12/5/02 SGCO) 146G6
REF PART# DESCRIPTION QTY
1 45-1797 CONTROLLER - mP-G (w/o chip) 1
2 40-812 CHIP - eprom 1
55-3000 SCREW - controller 8
55-2996 LOCKWASHER 8
55-2001 FLATWASHER 8
3 91-7143 BEZEL 1
4 33-2797 • GASKET - bezel 2
5 91-7142 • WINDOW - bezel 1
6 91-8680 COVER - mP-G 1
7 99-7246 STRIP - gasket (9.7 & 10.2 lg) A/R
8 91-8681 NAMEPLATE - cover, microprocessor 1
9 41-2527 HARNESS - on/off 1
10 44-1357 • SWITCH - on/off 1
44-5620 • CONNECTOR (2 pin, male) 1
11 44-739 • BOOT - switch 1
12 41-2528 BOARD - pc (indicator) 1
13 91-1277 RETAINER - harness connector 1
55-2262 RIVET - retainer 1
55-3550 FLATWASHER 1
55-3256 SCREW - board 4
55-2998 LOCKWASHER 4
55-3013 FLATWASHER 4
14 41-2529 HARNESS - indicator 1
15 44-5224 • CONNECTOR (4 pin, female) 1
16 44-5622 • CONNECTOR (6 pin, female) 1

64
 158C2 MAIN HARNESS ASSEMBLY
Revised
6/20/00

MAIN HARNESS
ASSEMBLY
158C2
6/20/00

65
Revised
6/20/00 MAIN HARNESS ASSEMBLY 158C2
REF PART# DESCRIPTION QTY
1 41-3614 HARNESS - main 1
2 44-9585 • PLUG (2 pin, see 112D9) 3
3 44-9586 • WEDGE (2 pin, see 112D9) 3
4 44-5622 • CONNECTOR (6 pin, female) 2
5 55-5719 • CONNECTOR (8 pin, female) 1
6 44-5219 • CONNECTOR (2 terminal, female) 2
7 44-6451 • CONNECTOR (1 pin, female) 2
8 44-5030 • CONNECTOR (6 pin, female) 1
9 44-5620 • CONNECTOR (2 pin, male) 1
10 44-5814 • CONNECTOR (2 terminal, female) 1

66
 112D9 DEUTSCH IN-LINE CONNECTORS
Revised
8/30/02

DEUTSCH IN-LINE
CONNECTORS
112D9
8/30/02

67
Revised
8/30/02 DEUTSCH IN-LINE CONNECTORS 112D9
REF PART# DESCRIPTION QTY
1 44-9700 TERMINAL - socket (w/ 6 in wire lead) 2
44-9587 TERMINAL - socket (without wire) 2
2 44-9585 PLUG (2 pin, w/ seal) 1
3 33-2392 SEAL 1
4 44-9586 WEDGE 1
5 44-9590 WEDGE 1
6 44-9589 RECEPTACLE (2 pin) 1
7 44-9701 TERMINAL - pin (w/ 6 in wire lead) 2
44-9591 PIN - terminal (w/o wire) 2
8 44-9631 CONNECTOR (3 pin, w/ seal) 1
9 33-2393 SEAL 1
10 44-9536 WEDGE 1
11 44-9545 WEDGE 1
12 44-9544 RECEPTACLE (3 pin) 1
13 44-8935 PLUG (4 pin, w/ seal) 1
14 33-2394 SEAL 1
15 44-8936 WEDGE 1
16 44-8918 WEDGE 1
17 44-8915 RECEPTACLE (4 pin) 1
18 44-8920 CONNECTOR (6 pin, w/ seal) 1
19 33-2395 SEAL 1
20 44-8917 WEDGE 1
21 44-8921 WEDGE 1
22 44-8914 CONNECTOR (6 pin) 1
23 44-9903 PLUG (8 pin, w/ seal) 1
24 33-2396 SEAL 1
25 44-9902 WEDGE 1
26 44-9901 WEDGE 1
27 44-9900 RECEPTACLE (8 pin) 1
28 44-9600 PLUG (12 pin, w/ seal) 1
29 33-2397 SEAL 1
30 44-9601 WEDGE 1
31 44-9905 WEDGE 1
32 44-9904 RECEPTACLE (12 pin) 1
33 41-2323 PLUG - assembly (w/ 6 in wires) 1
34 41-2322 RECEPTACLE - assembly (w/ 6 in wires) 1
35 41-2325 PLUG - assembly (w/ 6 in wires) 1
36 41-2324 RECEPTACLE - assembly (w/ 6 in wires) 1
37 41-2327 PLUG - assembly (w/ 6 in wires) 1
38 41-2326 RECEPTACLE - assembly (w/ 6 in wires) 1
39 44-9602 PIN - sealing A/R
40 44-9906 TAB - mounting (for all connectors except the 8 pin connector) A/R

68
112D9 DEUTSCH IN-LINE CONNECTORS
Revised
8/30/02

69
Revised
8/30/02 DEUTSCH IN-LINE CONNECTORS 112D9
REF PART# DESCRIPTION QTY
41 44-9907 TAB - mounting (for 8 pin connector only) A/R
42 204-703 KIT - crimper (w/ terminals) 1
204-1038 • TOOL - crimper 1
204-799 • TOOL - wedge remover 1

70
 131B4 EXCITER ASSEMBLY
Revised
3/20/98

EXCITER ASSEM-
BLY
131B4
3/20/98

71
Revised
3/20/98 EXCITER ASSEMBLY 131B4
REF PART# DESCRIPTION QTY
45-1719 EXCITER 1
1 44-3351 • RESISTOR 2
55-3123 • SCREW - resistor 2
55-3507 • SCREW - resistor (3/4 lg) 1
55-431 • FLATWASHER 4
55-1511 • LOCKWASHER 2
55-3006 • WASHER - shoulder 2
55-2752 • NUT 2
2 44-5354 • RESISTOR 1
55-3506 • SCREW - resistor (10-32 x 1) 1
55-3507 • SCREW - resistor (10-32 x 3/4) 1
55-3469 • WASHER - shoulder 2
55-401 • FLATWASHER 6
55-1852 • LOCKWASHER 3
55-346 • NUT 4
3 44-4108 • RECTIFIER (see 119G2) 1
4 44-3224 • TRANSFORMER - current 1
5 55-3520 • SPACER 8
6 44-4902 • SPACER 4
7 55-6433 • STUD - transformer 8
8 55-431 • FLATWASHER 8
55-396 • LOCKWASHER 8
9 55-2752 • NUT 8
10 91-7339 • PLATE - rectifier (see 131B5) 1
11 55-6828 • CLAMP - harness (9/16) 1
55-1350 • CLAMP - harness (3/8) 1
12 44-5712 • CONNECTOR & HARNESS - voltage regulator 1
13 41-1615 • TRANSFORMER (incl 14 & 15) 1
14 41-1421 •• SOCKET (12 contact, tin plated terminals) 1
15 41-1420 •• PLUG (12 contact, tin plated terminals) 1
16 44-4901 • COVER - connector 2
17 55-3355 • SCREW - connector cover 4
18 55-2851 • SCREW - diode 1
55-3508 • FLATWASHER 3
55-3509 • LOCKWASHER 2
55-3524 • WASHER - shoulder 1
55-3525 • NUT 2

72
131B4 EXCITER ASSEMBLY
Revised
3/20/98

73
Revised
3/20/98 EXCITER ASSEMBLY 131B4
REF PART# DESCRIPTION QTY
19 41-2533 • RECTIFIER 1
41-1974 • INSULATOR - rectifier 1
20 55-857 • SCREW - diode 1
55-406 • FLATWASHER 2
55-3524 • WASHER - shoulder 1
55-5761 • LOCKWASHER 1
55-295 • NUT 1
21 44-4208 • PLATE - assembly (incl items 1, 2, 3, 16, 18, 19 & 20) 1
99-3566 •• PLATE 1
22 44-6181 • CAPACITOR 1
23 91-7528 • PLATE - capacitor 1
24 55-5237 • SPACER - standoff 2
55-735 • SCREW - plate 2
25 55-2330 • BANDWRAP 2
26 99-3427 • MOUNT - bandwrap 2
55-3583 • RIVET - mount 2
27 44-3345 REGULATOR - voltage (see control box) 1

74
 119G2 RECTIFIER GROUP
Revised
7/8/96

RECTIFIER
GROUP
119G2
7/8/96

75
Revised
7/8/96 RECTIFIER GROUP 119G2
REF PART# DESCRIPTION QTY
1 44-4108 RECTIFIER 1
2 99-3564 PLATE - heat sink (top) 1
203-454 MASTIC - heat transfer A/R
3 99-3563 PLATE - heat sink (rectifier) 1
4 55-735 SCREW - rectifier plate 2
5 55-1266 FLATWASHER 2
6 55-3233 LOCKWASHER 2
7 55-3519 NUT 2

76
 131B5 RECTIFIER PLATE GROUP
Revised
8/23/00

RECTIFIER PLATE
GROUP
131B5
8/23/00

77
Revised
8/23/00 RECTIFIER PLATE GROUP 131B5
REF PART# DESCRIPTION QTY
1 91-7339 PLATE - rectifier 1
2 44-4108 RECTIFIER - 3 phase (15 amp) 2
55-3580 SCREW - rectifier 4
55-415 LOCKWASHER 4
3 41-1614 DIODE (D4) 1
4 41-1613 DIODE (D5) 1
5 33-1055 GROMMET 1
6 44-2558 BOARD - terminal 1
55-735 SCREW - board 2
55-1266 FLATWASHER 2
55-415 LOCKWASHER 2
7 91-7527 MARKSTRIP 1
8 41-1612 BUSBAR 1
9 44-3181 BREAKER - circuit 1
55-5046 SCREW - breaker 1
55-366 LOCKWASHER 1
55-411 FLATWASHER 1
55-2752 NUT - breaker terminal 2
55-396 LOCKWASHER 2
55-431 FLATWASHER 2
10 91-7340 MARKSTRIP 1

78
 ALTERNATOR GROUP (SGCO 2000, SGSM 2000,
166C8 SGCM 2000)
Revised
12/5/02

ALTERNATOR
GROUP (SGCO
2000, SGSM 2000,
SGCM 2000)
166C8
12/5/02

79
 ALTERNATOR GROUP (SGCO 2000, SGSM 2000,
Revised
12/5/02 SGCM 2000) 166C8
REF PART# DESCRIPTION QTY
1 404-150 ALTERNATOR 1
2 45-1956 • STATOR 1
3 45-1955 • ROTOR (incl blower & flex disc) 1
4 77-2654 •• BLOWER 1
5 11-9482 •• DISC - flex 1
6 77-2747 •• BEARING 1
7 44-4678 • RECTIFIER - positive 1
8 44-4679 • RECTIFIER - negative 1
9 55-9820 SPACER - fan 6
10 55-9818 SCREW - fan 7
55-9817 LOCKWASHER 7
55-9819 FLATWASHER 6
11 55-1587 SCREW - cover 2
12 55-2086 FLATWASHER 2
55-1800 LOCKWASHER 2
13 55-3539 CONNECTOR - barb 1
33-1056 O-RING 1
55-2636 NUT 1
14 99-3583 PLATE - cover 1
15 41-1418 PLUG - exciter (12 contact) 1
16 44-5620 CONNECTOR (2 pin) 1
17 33-1062 GASKET - plate 1
18 98-5035 HOSE - harness (cut to 26.0 inches) A/R
19 55-8137 SCREW - disc to flywheel 6
55-7066 LOCKWASHER 6
55-6988 FLATWASHER 6
20 55-9497 PIN - dowel 2
21 91-3439 COVER - harness 1
22 33-1420 GASKET - cover 1

80
 158C6 BATTERY & CABLE GROUP
Revised
6/18/01

BATTERY & CABLE

GROUP
158C6
6/18/01

81
Revised
6/18/01 BATTERY & CABLE GROUP 158C6
REF PART# DESCRIPTION QTY
1 203-387 BATTERY - maintenance free 1
2 92-269 STRAP - battery holddown 1
3 41-1551 CABLE - negative (42 in) 1
4 44-5709 CABLE - power (positive, 36 in) 1
5 55-4436 • NUT 2
6 91-7530 BRACKET - battery cable 1
55-1587 SCREW - bracket 2
55-2086 FLATWASHER 2
55-4953 LOCKWASHER 2
55-4377 CLAMP 4
7 55-5022 SCREW - strap to engine 1
8 55-3238 LOCKWASHER 2
9 55-2958 FLATWASHER 2
10 41-808 STRAP - ground (20 in lg) 1
11 55-1587 SCREW - strap to frame 1
12 55-2993 LOCKWASHER (internal tooth) 2
13 55-2086 FLATWASHER 2
14 55-5943 NUT 1
15 91-4146 ROD - holddown 2
55-4954 NUT - holddown 2
55-2958 FLATWASHER 2

82
 158C3 STRUCTURAL COMPONENTS
Revised
6/26/00

STRUCTURAL
COMPONENTS
158C3
6/26/00

83
Revised
6/26/00 STRUCTURAL COMPONENTS 158C3
REF PART# DESCRIPTION QTY
1 98-5720 PANEL - curbside 1
2 98-5718 PANEL - top center 1
55-2969 SCREW - panel 9
55-2959 LOCKWASHER 9
3 98-5719 PANEL - top left 1
4 92-251 CHANNEL - top, curbside 1
5 92-252 SUPPORT - right 1
55-2977 SCREW - support 3
55-2086 FLATWASHER 3
55-1800 LOCKWASHER 3
6 92-249 CHANNEL - center 1
7 92-250 SUPPORT - center 1
8 92-253 CHANNEL - top, roadside 1
9 92-254 SUPPORT - vertical, roadside 1
10 91-6822 BUMPER - bulkhead 1
99-8994 SPACER - bumper 4
55-3121 SCREW - bumper 4
55-2086 FLATWASHER 4
55-1800 LOCKWASHER 4
11 98-5717 SUPPORT - frame, top shelf 1
12 98-5716 FRAME - fuel tank (see 130G3) 1
98-5724 FRAME - fuel tank (header pin, option 062312) 1
91-9499 ROD - mounting (clip-on) 2
13 98-5721 DOOR - curbside 1
14 98-5722 DOOR - roadside 1
15 92-260 LATCH - door 2
16 99-1175 LATCH - door A/R
91-5315 SPACER - door latch 4
55-3003 SCREW - latch 8
55-3013 FLATWASHER 32
55-3014 LOCKWASHER 8
55-2999 NUT 8
55-7527 SCREW - door 6
55-7729 WASHER - belleville 6
17 91-3161 BRACKET - clip-on (left, see 105C8) 1
91-3162 BRACKET - clip-on (right, see 105C8) 1
18 91-7227 BOLTSTRIP - bracket 4
55-4767 FLATWASHER 8
55-5418 NUT 4
19 91-2382 SPACER - bracket 2
20 92-266 COVER - retainer bolt, curbside (incl latch #16) 1
21 Not Used

84
158C3 STRUCTURAL COMPONENTS
Revised
6/26/00

85
Revised
6/26/00 STRUCTURAL COMPONENTS 158C3
REF PART# DESCRIPTION QTY
22 92-267 COVER - retainer bolt, roadside (incl latch #16) 1
23 99-3898 STRIP - bumper 6
24 91-7229 BAR - locking 2
25 91-7230 LANYARD 2
91-7231 LANYARD 2
91-6826 RING - key 4
91-6825 COTTER - loop 4
26 92-264 BUMPER - lower 2
27 92-265 SPACER - bumper 2
55-3121 SCREW - bumper 2
55-2086 FLATWASHER 2
55-4953 NUT 2

86
 158C5 STRUCTURAL COMPONENTS (REAR VIEW)
Revised
6/23/00

STRUCTURAL
COMPONENTS
(REAR VIEW)
158C5
6/23/00

87
Revised
6/23/00 STRUCTURAL COMPONENTS (REAR VIEW) 158C5
REF PART# DESCRIPTION QTY
1 92-261 SHIELD - radiator fan 1
55-8979 • INSERT 2
2 92-262 SHIELD - muffler 1
55-8979 • INSERT 4
3 92-263 SHIELD - exhaust tube 1
55-8979 • INSERT 3
55-1587 SCREW - shield 9
55-1800 LOCKWASHER 9
4 91-6831 STRIP - foam 1

88
 105C8 UNIT MOUNTING BRACKET
Revised
9/6/94

UNIT MOUNTING
BRACKET
105C8
9/6/94

89
Revised
9/6/94 UNIT MOUNTING BRACKET 105C8
REF PART# DESCRIPTION QTY
91-3161 BRACKET (lefthand) 1
91-3162 BRACKET (righthand) 1
1 55-2925 • PIN - spring (slotted) 1
2 91-3160 • SHAFT - clamp 1
3 55-6030 • SCREW - shoulder 2
4 91-112 • BASE - clamp 1
5 55-4021 • FITTING - grease 2
55-2155 • SCREW - set 2
6 91-114 • PAW - clamp 1
7 55-4118 • NUT 2
8 91-113 • HANDLE - clamp 1
9 55-6028 • WASHER - spring 2
10 55-6029 • WASHER - special 1
11 55-6027 • NUT 1

90
 146G2 NAMEPLATES
Revised
5/17/01

NAMEPLATES
146G2
5/17/01

91
Revised
5/17/01 NAMEPLATES 146G2
REF PART# DESCRIPTION QTY
1 91-2388 NAMEPLATE - TK (CGCO & SGCO) 1
91-4510 NAMEPLATE - TK (CGCM & SGCM) 1
2 91-6284 NAMEPLATE - 15 KW 1
3 91-7171 NAMEPLATE - California Proposition 1
4 91-5703 NAMEPLATE - Service Information Records Pouch 1
5 91-2384 NAMEPLATE - Caution Left 1
6 99-8583 NAMEPLATE - Clean Filter Screen 1
7 91-9918 NAMEPLATE - Thermo King (black letters) 1
91-9919 NAMEPLATE - Thermo King (white letters) 1
8 91-2383 NAMEPLATE - Caution Right 1
9 99-9234 NAMEPLATE - Fan Universal 1
10 91-4512 NAMEPLATE - arrow 1
11 91-3423 NAMEPLATE - 460V 1
12 91-4148 NAMEPLATE - Installation Instructions (CGCO & SGCO) 1
91-3425 NAMEPLATE - Installation Instructions (CGCM & SGCM) 1
13 91-338 NAMEPLATE - Document Holder 1
14 91-7012 NAMEPLATE - Radiator Fill 1
15 99-7314 NAMEPLATE - Coolant Level 1
16 91-7013 NAMEPLATE - Maintenance 1
17 99-3522 NAMEPLATE - Caution 460 Volts 1
18 99-4732 NAMEPLATE - 460 Volts 1
19 91-2389 NAMEPLATE - Diesel Fuel Only 1
20 99-4660 NAMEPLATE - Positive 1
21 99-4661 NAMEPLATE - Negative 1
22 99-6596 NAMEPLATE - Coolant 1
23 91-8684 NAMEPLATE - FHWA 1
24 91-8685 NAMEPLATE - Wiring Diagram 1
25 91-8686 NAMEPLATE - Schematic Diagram 1
26 91-8687 NAMEPLATE - Smart Gen-Set Menu List 1
92-300 NAMEPLATE - Smart Gen-Set Menu List (Spanish) 1
27 91-8688 NAMEPLATE - Smart Gen-Set (SGCO) 1
92-1362 NAMEPLATE - Smart Gen-Set operating instructions (Span- 1
ish SGCO 2000-151)
91-9506 NAMEPLATE - Smart Gen-Set (SGSM) 1
91-9507 NAMEPLATE - Smart Gen-Set (SGCM) 1
28 91-8689 NAMEPLATE - Smart Gen-Set Operating Instructions 1
92-275 NAMEPLATE - Smart Gen-Set Operating Instructions (Span- 1
ish)
29 91-8810 NAMEPLATE - CE 1
30 91-8699 NAMEPLATE - Operating Instructions (CGCM) 1
91-9920 NAMEPLATE - Operating Instructions (CGSM) 1
31 91-8700 NAMEPLATE - Schematic/Wiring Diagram (CGCO & SGCO) 1
32 91-8746 NAMEPLATE - Ingersoll Rand (black letters) 1

92
146G2 NAMEPLATES
Revised
5/17/01

93
Revised
5/17/01 NAMEPLATES 146G2
REF PART# DESCRIPTION QTY
91-9043 NAMEPLATE - Ingersoll Rand (white) 1
33 91-3424 NAMEPLATE - 230V 1
34 99-3407 NAMEPLATE - Caution 230 Volts 1
35 99-9938 NAMEPLATE - Caution, Start/Stop 1
36 99-9939 NAMEPLATE - Caution, Start/Stop (multi-language) 1
37 91-9269 NAMEPLATE - Texaco 1
38 92-109 NAMEPLATE - 1245 Max Weight KG. 1

94
 INDEX NUMERICAL BY PART NUMBER

101-317 6 11-7499 28 11-8944 20

101-318 6 11-7707 28 11-8945 22
101-321 22, 30, 42 11-8047 42 11-8947 18
101-330 6 11-8048 44 11-8948 18
101-331 30 11-8653 44 11-8949 18
10-242 40, 42, 44 11-8667 12 11-8950 18
10-243 42 11-8668 24 11-8951 18
10-317 46 11-8671 14 11-8952 18
11-2457 46 11-8672 14 11-8953 18
11-2610 46 11-8673 20 11-8954 18
11-3733 46 11-8675 26 11-8955 18
11-4367 42 11-8680 28 11-8956 18
11-4372 40, 42, 44 11-8681 28 11-8957 18
11-4380 42 11-8682 28 11-8958 18
11-4607 50 11-8715 32, 34 11-8959 18
11-4693 50 11-8718 44 11-8961 24
11-4841 42 11-8719 44 11-8962 24
11-4941 40, 42, 44 11-8728 32 11-8963 24
11-4959 44 11-8729 32 11-8964 24
11-5082 8 11-8730 32 11-8965 24
11-5091 8 11-8731 32 11-8970 28
11-5103 14 11-8823 32 11-8971 28
11-5170 30 11-8858 46 11-8972 28
11-5320 42 11-8887 44 11-8973 28
11-5499 6 11-8888 52 11-8974 28
11-6031 10 11-8891 52 11-8975 28
11-6106 34 11-8900 46 11-8976 28
11-6108 34 11-8901 46 11-8977 28
11-6110 32 11-8913 50 11-8978 34
11-6125 30 11-8914 6 11-8979 32
11-6555 6 11-8915 6 11-8984 12
11-6567 14 11-8916 6 11-8992 24
11-6680 6 11-8917 6 11-8993 22
11-6681 22 11-8918 6 11-8994 14
11-6693 14 11-8919 6 11-8995 24
11-6698 16 11-8920 8 11-8996 26
11-6702 14 11-8921 8 11-8997 32
11-6703 14 11-8922 8 11-8998 28
11-6704 14 11-8923 12 11-9015 42
11-6707 14, 38 11-8924 10 11-9016 42
11-6708 14 11-8925 14 11-9017 42
11-6716 22 11-8926 14 11-9182 24, 40
11-6717 22 11-8927 14 11-9202 22
11-6719 18, 22 11-8928 14 11-9203 22
11-6721 22 11-8929 14 11-9205 30
11-6722 22 11-8930 14 11-9248 22
11-6724 18 11-8931 14 11-9249 24
11-6786 34 11-8932 16 11-9250 24, 38
11-6787 34 11-8933 16 11-9256 26
11-6788 34 11-8934 16, 38 11-9261 22
11-6789 34 11-8935 14, 38 11-9286 48
11-6790 34 11-8936 16 11-9287 50
11-6791 32 11-8937 14, 38 11-9288 50
11-6793 32 11-8938 14 11-9289 46
11-6794 32 11-8939 14 11-9338 12
11-6797 32 11-8940 14 11-9342 42
11-6829 40 11-8941 14 11-9354 24
11-7382 24, 40 11-8942 16 11-9446 32
11-7433 28, 42 11-8943 20 11-9447 24

INDEX - 1
 INDEX NUMERICAL BY PART NUMBER

11-9448 12 33-2458 40 41-2159 36

11-9482 80 33-2759 10 41-2160 36
11-9499 26, 50 33-2762 14, 38 41-2161 36
11-9562 30 33-2764 20, 38 41-2162 36
11-9589 26 33-2765 20, 38 41-2191 60
11-9612 30 33-2767 26, 38 41-2317 6
11-9613 30 33-2768 26, 38 41-2322 68
11-9617 32 33-2771 28 41-2323 68
12-633 50 33-2797 64 41-2324 68
12-743 6 33-2854 46 41-2325 68
12-745 12 33-2931 24, 38 41-2326 68
12-746 12 33-2932 16, 38 41-2327 68
12-747 14 33-2933 8 41-2330 50
12-749 18 33-2934 16, 38 41-2444 30, 36
12-750 18 33-2935 14, 38 41-2527 64
12-799 50 33-2936 20, 38 41-2528 64
12-800 48 33-2937 20, 38 41-2529 64
12-823 10 33-2938 24, 38 41-2530 62
203-348 8, 12, 38 33-2940 28 41-2533 74
203-387 82 33-2941 28 41-2585 62
203-393 42 33-2942 28, 38 41-2586 62
203-454 76 33-2969 10, 38 41-2906 62
204-1011 8 33-2970 24 41-3403 58
204-1038 70 33-2974 10, 38 41-3404 58
204-1056 32 33-3060 12, 40 41-3614 58, 66
204-1083 30 33-3096 26, 38 41-385 40
204-427 54 33-3097 26, 38 41-402 12, 40
204-542 32 33-3098 26, 38 41-4306 30
204-703 70 33-3167 58 41-4470 12
204-799 70 33-3168 58 41-808 82
204-952 10 33-3204 30 41-893 60
204-994 10 33-3259 38 41-895 62
30-248 38 33-3263 38 44-1357 64
30-267 30 33-3512 14, 38 44-1458 62
33-1055 78 33-3689 30 44-2558 78
33-1056 58, 80 33-3690 30 44-3181 78
33-1062 80 404-150 80 44-3224 72
33-1420 80 40-812 64 44-3345 58, 74
33-1500 8, 38 41-1418 58, 80 44-3351 72
33-1530 30 41-1420 72 44-4108 72, 76, 78
33-1531 38 41-1421 72 44-4208 74
33-1745 26 41-1551 82 44-4678 80
33-1749 28 41-1612 78 44-4679 80
33-1753 30 41-1613 78 44-4901 72
33-1910 8, 38 41-1614 78 44-4902 72
33-1952 8, 38 41-1615 72 44-5030 58, 66
33-1953 8, 30, 38 41-1818 52 44-5219 66
33-1954 8, 12, 38 41-1974 74 44-5224 64
33-1970 30 41-2147 20 44-5354 72
33-1973 30 41-2149 36 44-5555 58
33-1975 32, 38 41-2150 36 44-5620 64, 66, 80
33-2230 30 41-2151 36 44-5622 58, 62, 64, 66
33-2314 48 41-2152 36 44-5709 82
33-2392 68 41-2153 36 44-5712 72
33-2393 68 41-2154 36 44-5719 58
33-2394 68 41-2155 36 44-5814 58, 66
33-2395 68 41-2156 36 44-6181 74
33-2396 68 41-2157 36 44-6451 66
33-2397 68 41-2158 36 44-739 64

INDEX - 2
 INDEX NUMERICAL BY PART NUMBER

44-8244 62 55-2262 60, 62, 64 55-3525 72

44-8883 40 55-229 40 55-3539 58, 80
44-8914 68 55-2330 74 55-3550 62, 64
44-8915 68 55-2332 46 55-3580 78
44-8917 68 55-2554 50 55-3583 74
44-8918 68 55-2557 56 55-3595 56
44-8920 68 55-2636 58, 80 55-366 78
44-8921 68 55-2752 72, 78 55-3744 40
44-8935 68 55-2796 50 55-396 72, 78
44-8936 68 55-2851 72 55-3991 46
44-9282 58 55-2925 90 55-401 62, 72
44-9298 40, 56 55-295 74 55-4021 90
44-9536 68 55-2955 52, 58 55-406 74
44-9544 68 55-2957 50 55-411 78
44-9545 68 55-2958 42, 46, 48, 56, 82 55-4118 90
44-9585 66, 68 55-2959 42, 46, 48, 54, 56, 84 55-415 78
44-9586 66, 68 55-2964 40, 58 55-4203 42
44-9587 68 55-2965 58 55-431 72, 78
44-9589 68 55-2969 46, 84 55-4377 82
44-9590 68 55-2977 48, 50, 52, 58, 84 55-4436 82
44-9591 68 55-2979 50, 58 55-4515 40
44-9600 68 55-2990 58 55-4600 6
44-9601 68 55-2993 82 55-4607 32
44-9602 68 55-2996 58, 60, 62, 64 55-4613 46
44-9631 68 55-2998 40, 62, 64 55-4615 30
44-9700 68 55-2999 84 55-4622 8, 24, 38
44-9701 68 55-3000 62, 64 55-4644 24
44-9900 68 55-3003 84 55-4645 24
44-9901 68 55-3006 72 55-4670 30
44-9902 68 55-3013 40, 62, 64, 84 55-4733 24, 38
44-9903 68 55-3014 84 55-4750 28
44-9904 68 55-3018 50 55-4767 84
44-9905 68 55-3021 52 55-4952 56
44-9906 68 55-3031 40 55-4953 12, 40, 48, 50, 52, 58,
44-9907 70 55-3045 50 82, 86
45-1688 36 55-3059 58 55-4954 42, 46, 82
45-1719 58, 72 55-3089 48 55-4955 46
45-1797 62, 64 55-3099 60 55-5022 42, 46, 48, 82
45-1823 36 55-3121 84, 86 55-5023 50
45-1955 80 55-3123 72 55-5046 78
45-1956 80 55-3233 76 55-5081 12, 40
51-269 30 55-3238 82 55-5090 50
55-1266 76, 78 55-3256 64 55-5138 14
55-1350 72 55-3304 56 55-5205 56
55-1511 72 55-3355 72 55-5237 74
55-1587 12, 40, 80, 82, 88 55-3364 44 55-5279 62
55-1592 46 55-346 62, 72 55-5400 50, 52
55-1800 48, 50, 52, 58, 80, 84, 88 55-3469 72 55-5418 84
55-1819 32 55-3472 46, 48 55-5617 44
55-1852 62, 72 55-3490 42 55-5719 66
55-193 6 55-3506 72 55-5761 74
55-2001 40, 58, 62, 64 55-3507 72 55-5763 16, 20, 24
55-2038 56 55-3508 72 55-5768 8, 14, 16, 22, 24, 26
55-2086 12, 40, 48, 50, 52, 58, 55-3509 72 55-5770 36
80, 82, 84, 86 55-3512 56 55-5772 20
55-2114 48 55-3513 40 55-5780 26
55-2155 90 55-3519 76 55-5784 8, 30
55-2201 58 55-3520 72 55-5791 20
55-2202 58 55-3524 72, 74 55-5792 14, 26

INDEX - 3
 INDEX NUMERICAL BY PART NUMBER

55-5794 10 55-8665 40 91-2384 92

55-5801 16 55-8717 20 91-2388 92
55-5803 14 55-8752 50 91-2389 92
55-5809 8, 12, 22, 24 55-885 6 91-3160 90
55-5810 8, 30 55-8853 16 91-3161 84, 90
55-5816 8, 10, 18 55-8854 8 91-3162 84, 90
55-5822 30 55-8855 10 91-338 92
55-5834 18 55-8856 10 91-3423 92
55-5943 82 55-8857 10 91-3424 94
55-5989 6 55-8858 16 91-3425 92
55-6027 90 55-8859 14 91-3439 80
55-6028 90 55-8860 14 91-3542 16
55-6029 90 55-8861 20 91-4146 82
55-6030 90 55-8862 20 91-4148 92
55-6177 6, 24 55-8863 22 91-4510 92
55-6188 8, 20, 24, 26 55-8864 18 91-4512 92
55-6191 10, 24 55-8865 18 91-4823 12
55-6193 14 55-8867 24 91-5315 84
55-6195 32 55-8868 24 91-5703 92
55-6229 6 55-8869 24 91-6284 92
55-6234 8 55-8870 30 91-6822 84
55-6236 8, 20 55-8871 28 91-6825 86
55-6237 8, 12 55-8872 28 91-6826 86
55-6245 14 55-8894 36 91-6831 88
55-6246 12, 14 55-8895 36 91-6841 58
55-6248 26 55-8896 36 91-7012 92
55-6249 18 55-8897 36 91-7013 92
55-6250 18 55-8898 36 91-7142 64
55-6251 24 55-8967 22 91-7143 64
55-6254 22 55-8979 88 91-7171 92
55-6367 8, 28 55-9011 50 91-7191 12
55-6433 72 55-9091 50 91-7217 52
55-6526 50 55-9127 62 91-7227 84
55-6731 52 55-9167 12 91-7229 86
55-6764 54 55-9400 60 91-7230 86
55-6814 56 55-9497 80 91-7231 86
55-6828 72 55-9817 80 91-7233 48
55-6988 56, 80 55-9818 80 91-7234 48
55-6999 56 55-9819 80 91-7339 72, 78
55-7000 56 55-9820 80 91-7340 78
55-7062 40 77-1345 54 91-7497 52
55-7066 56, 80 77-1426 26 91-7527 78
55-735 74, 76, 78 77-1427 26 91-7528 74
55-7412 56 77-1428 26 91-7530 82
55-7527 84 77-2468 36 91-7555 46
55-7616 40 77-2469 36 91-7782 52
55-7660 54 77-2470 36 91-8035 50
55-7729 84 77-2471 36 91-8036 50
55-790 36, 48 77-2654 80 91-8112 36
55-8116 46 77-2673 18, 54 91-860 58
55-8137 56, 80 77-2747 80 91-8677 40
55-8430 60 78-1108 54 91-8678 46
55-8437 12 78-618 54 91-8680 64
55-8442 14 91-112 90 91-8681 64
55-8443 26 91-113 90 91-8684 92
55-8448 30 91-114 90 91-8685 92
55-857 74 91-1277 60, 62, 64 91-8686 92
55-8620 30, 32, 38 91-2382 84 91-8687 92
55-8626 32 91-2383 92 91-8688 92

INDEX - 4
 INDEX NUMERICAL BY PART NUMBER

91-8689 92 99-1655 50
91-8699 92 99-1916 56
91-8700 92 99-3407 94
91-8744 46 99-3427 74
91-8746 92 99-3522 92
91-8810 92 99-3563 76
91-8920 62 99-3564 76
91-9043 94 99-3566 74
91-9269 94 99-3583 80
91-9499 84 99-3649 56
91-9506 92 99-3855 58
91-9507 92 99-3898 86
91-9918 92 99-4660 92
91-9919 92 99-4661 92
91-9920 92 99-4732 92
92-109 94 99-6596 92
92-1350 50 99-7246 64
92-1362 92 99-7314 92
92-224 56 99-8301 50
92-225 56 99-8583 92
92-226 56 99-8994 84
92-228 56 99-9234 92
92-229 56 99-9938 94
92-248 54 99-9939 94
92-249 84
92-250 84
92-251 84
92-252 84
92-253 84
92-254 84
92-255 58
92-256 48
92-258 40
92-260 84
92-261 88
92-262 88
92-263 88
92-264 86
92-265 86
92-266 84
92-267 86
92-269 82
92-275 92
92-300 92
98-5035 60, 80
98-5711 50
98-5716 84
98-5717 84
98-5718 84
98-5719 84
98-5720 84
98-5721 84
98-5722 84
98-5723 50
98-5724 84
99-1175 84
99-1400 46
99-1433 56
99-1642 56

INDEX - 5
INDEX NUMERICAL BY PART NUMBER

INDEX - 6

A BRACKET - plug support 58
ADAPTER 28
ADAPTER - air intake 46
ADAPTER - compression tester 32
ALTERNATOR 80
ANGLE - radiator 50
ARM - rocker 14
ARMATURE 36
B BUSHING - camshaft 6
BAFFLE - breather 14
BALL 24
BALL - check 44
BANDWRAP 46, 74
BANJO - fuel inlet 32
BANJO - fuel return 32
BAR - locking 86
BASE - clamp 90
BASE - fuel filter 42
BATTERY - maintenance free 82
BEARING 36, 80
BEARING - ball 36
BEARING - connecting rod 18
BEARING - main 6
BEARING - thrust 6, 22
BELT - fan & water pump 54
BEZEL 64
BLOCK - cylinder 6
BLOWER 80
BOARD - pc 64
BOARD - pc timer 60
BOARD - printed circuit,
interconnecting 62
BOARD - relay 62
BOARD - terminal 58, 78
BOLT - air bleed 32
BOLT - bearing cap 6
BOLT - connecting rod 18
BOLT - eye 24
BOLT - flywheel 18
BOLT - fuel control 30
BOLT - plate 22
BOLT - thru 36
BOLT - v-pulley 18
BOLTSTRIP - bracket 84
BOOT - switch 64
BOX - control 58
BRACKET 90
BRACKET - battery cable 82
BRACKET - clamp 46
BRACKET - clip 12
BRACKET - clip-on 84
BRACKET - engine 56
BRACKET - exhaust tube 48
BRACKET - filter 24
BRACKET - generator, bottom 56
BRACKET - generator, rear 56
BRACKET - oil sensor 40
BRACKET - overflow tank 52
INDEX - 1
INDEX ALPHABETICAL BY DESCRIPTION
BRACKET - radiator 50
BRACKET - relay board 62
BREAKER - circuit 78
BRUSH 36
BUMPER - bulkhead 84
BUMPER - lower 86
BUSBAR 78
BUSHING 24, 50
BUSHING - idler gear 22
BUSHING - piston pin 18
C DIODE 78
CABLE - negative 82
CABLE - power 82
CABLE - ribbon 62
CAM - feed pump 22
CAMSHAFT 22
CAP 12, 32
CAP - bearing 6
CAP - drain hose 40
CAP - fuel tank 44
CAP - hose 12
CAP - oil fill 8
CAP - radiator 50
CAP - valve 16
CAP & CHAIN - overflow tank 50
CAPACITOR 74
CASE - gear 8
CASE - oil seal 10
CHANNEL - center 84
CHANNEL - top, curbside 84
CHANNEL - top, roadside 84
CHIP - eprom 64
CIRCLIP 18
CLAMP 32, 46, 82
CLAMP - air cleaner 46
CLAMP - harness 72
CLAMP - hose 14, 42, 46, 50, 52
CLAMP - oil cup 46
CLEANER - air 46
CLIP - hose 12, 40
CLUTCH - assembly 36
COIL - field 36
CONNECTOR 58, 62, 64, 66, 68, 80
CONNECTOR - barb 58, 80
CONNECTOR - hose 46
CONNECTOR & HARNESS - voltage
regulator 72
CONTROLLER - mP-G 62, 64
COTTER - loop 86
COVER 8
COVER - access 52
COVER - bottom 30
COVER - breather 14
COVER - connector 72
COVER - dust 36
COVER - gear case 8
COVER - harness 80
COVER - mP-G 58, 64
COVER - rear 36
COVER - retainer bolt, curbside 84
COVER - retainer bolt, roadside 86
COVER - side 30
COVER - sound shield 8
COVER - thermostat 26
COVER - valve 14
CRANKSHAFT 18
CUP - air cleaner 46
D
DIPSTICK 12
DISC - flex 80
DOOR - curbside 84
DOOR - roadside 84
DRAIN COCK 26
DRAIN COCK - radiator 50
E
ELBOW 42, 44
ELBOW - hose 12, 40
ELBOW - oil pressure switch 40
ELBOW - pipe 50
ENGINE 6
EXCITER 58, 72
F
FAN - radiator 54
FILTER - fuel 42
FILTER - oil 24, 40
FITTING - grease 90
FITTING - hose 40
FITTING - oil drain 12
FITTING - oil inlet 24
FLANGE 16
FLATWASHER 12, 40, 42, 46, 48, 50,
52, 56, 58, 62, 64, 72,
74, 76, 78, 80, 82, 84, 86
FLYWHEEL 18
FRAME - fuel tank 84
FUSE LINK 62
G
GASKET 24, 26, 28, 32, 38
GASKET - adhesive 8, 12, 38
GASKET - air heater 20, 38
GASKET - bezel 64
GASKET - bottom cover 30
GASKET - bracket 24
GASKET - cover 8, 80
GASKET - cylinder head 16, 38
GASKET - exhaust manifold 20, 38
GASKET - eye bolt 38
GASKET - flange 16, 38
GASKET - inlet 20
GASKET - intake manifold 20, 38

GASKET - joint 26
GASKET - muffler 48
GASKET - oil pump 24, 38
GASKET - oil seal case 10, 38
GASKET - pipe 24
GASKET - plate 80
GASKET - receptacle 58
GASKET - round 38
GASKET - side cover 30
GASKET - switch 12, 40
GASKET - thermostat case 38
GASKET - valve cover 14, 38
GASKET - water pump 26, 38
GAUGE - belt tension 54
GAUGE - fuel 44
GEAR 22
GEAR - camshaft 22
GEAR - crankshaft 18
GEAR - pump 22
GEAR - ring 18
GROMMET 78
GUIDE - valve 14
H 82, 84, 88
HANDLE - clamp 90
HANGER - overflow tank 50
HARNESS - indicator 64
HARNESS - main 58, 66
HARNESS - on/off 64
HARNESS - voltmeter 62
HEAD - cylinder 14
HEATER - air 20
HEATER - frost plug 6
HOLDER - brush 36
HOLDER - nozzle 34
HOSE 40, 42, 44
HOSE - air 46
HOSE - breather 46
HOSE - harness 80
HOSE - insulation 46
HOSE - main harness 60
HOSE - oil drain 12, 40
HOSE - outlet 52
HOSE - overflow 50
HOSE - radiator to engine 50
HOSE - water pump 50
HOSE - water pump to radiator 50
HOUSING - flywheel 10
HOUSING - gear 36
I NAMEPLATE - CE 92
INLET - intake manifold 20
INSERT 40, 50, 88
INSULATOR - rectifier 74
J 64
JOINT - breather 20
JOINT - pipe 28
JOINT - pump 26
INDEX ALPHABETICAL BY DESCRIPTION
JUMPER 62
K NAMEPLATE - Installation Instructions
KEEPER - valve 16
KEY - gear 18, 22
KIT - adapter & hose 46
KIT - crimper 70
KIT - gasket 30
KIT - gasket set 38
KIT - sleeve & eyelet 40, 42, 44
KNOB - valve cover 14
L Diagram 92
LANYARD 86
LATCH - door 84
LEVER 36
LEVER - control 30
LIFTER - engine 16
LINER - service 6
LOCKNUT 48, 52, 58
LOCKWASHER 36, 40, 42, 46, 48, 50,
52, 54, 56, 58, 60, 62,
64, 72, 74, 76, 78, 80,
M NAMEPLATE - Wiring Diagram 92
MANIFOLD - exhaust 20
MANIFOLD - intake 20
MARKSTRIP 58, 78
MASTIC - heat transfer 76
MAT - insulating 40
MOUNT - bandwrap 74
MOUNT - vibration 56
MUFFLER 48
N NUT - clamp 46
NAMEPLATE - 1245 Max Weight KG.
94
NAMEPLATE - 15 KW 92
NAMEPLATE - 230V 94
NAMEPLATE - 460 Volts 92
NAMEPLATE - 460V 92
NAMEPLATE - arrow 92
NAMEPLATE - California Proposition
92
NAMEPLATE - Caution 230 Volts 94
NAMEPLATE - Caution 460 Volts 92
NAMEPLATE - Caution Left 92
NAMEPLATE - Caution Right 92
NAMEPLATE - Caution, Start/Stop 94
NAMEPLATE - Clean Filter Screen 92
NAMEPLATE - Coolant 92
NAMEPLATE - Coolant Level 92
NAMEPLATE - cover, microprocessor
NAMEPLATE - Diesel Fuel Only 92
NAMEPLATE - Document Holder 92
NAMEPLATE - Fan Universal 92
NAMEPLATE - FHWA 92
NAMEPLATE - Ingersoll Rand 92, 94
92
NAMEPLATE - Maintenance 92
NAMEPLATE - Negative 92
NAMEPLATE - Operating Instructions
92
NAMEPLATE - Positive 92
NAMEPLATE - Radiator Fill 92
NAMEPLATE - Schematic Diagram 92
NAMEPLATE - Schematic/Wiring
NAMEPLATE - Service Information
Records Pouch 92
NAMEPLATE - Smart Gen-Set 92
NAMEPLATE - Smart Gen-Set Menu
List 92
NAMEPLATE - Smart Gen-Set
Operating Instructions 92
NAMEPLATE - Smart Gen-Set
operating instructions 92
NAMEPLATE - Texaco 94
NAMEPLATE - Thermo King 92
NAMEPLATE - TK 92
NOZZLE 34
NOZZLE - oil 22
NUT 8, 12, 14, 20, 22, 26, 28, 30, 40,
42, 46, 48, 50, 56, 72,
74, 76, 80, 82, 84, 86, 90
NUT - base 42
NUT - breaker terminal 78
NUT - cap 30
NUT - captive 58
NUT - exciter 58
NUT - ground 58
NUT - holddown 82
NUT - hose 40
NUT - hose fitting 44
NUT - jumper & link 62
NUT - nozzle case 34
NUT - terminal board 58
O
ORIFICE 24
ORIFICE - breather 14
ORIFICE - radiator 50
O-RING 8, 14, 28, 38, 46, 58, 80
O-RING - cap 8
O-RING - cover 14
O-RING - deflector check 30
O-RING - delivery 30
O-RING - dipstick 12
O-RING - fuel injection pump 38
O-RING - injection pump 8, 30
O-RING - joint 26
O-RING - screw 30
INDEX - 2
 INDEX ALPHABETICAL BY DESCRIPTION

O-RING - solenoid 30 RELAY 62 SCREW - lifter 16

O-RING - tappet 30 RELAY - mini 60 SCREW - muffler 48
O-RING - water pump 38 RESISTOR 72 SCREW - nozzle 22
RETAINER 24, 28, 32, 36 SCREW - oil base 12
P RETAINER - harness 60 SCREW - oil pump 24
PAD - radiator 52 RETAINER - harness connector 62, 64 SCREW - orifice 50
PANEL - curbside 84 RETAINER - nozzle 14 SCREW - panel 84
PANEL - top center 84 RETAINER - shaft 30 SCREW - pc board 62
PANEL - top left 84 RETAINER - spring 16 SCREW - pipe 24
PAW - clamp 90 RETAINER - valve 28 SCREW - plate 74
PIN 34 RING - key 86 SCREW - plug 8, 10, 24
PIN - dowel 8, 10, 18, 80 RING SET 18 SCREW - pump 26
PIN - piston 18 RIVET - mount 74 SCREW - radiator 50
PIN - sealing 68 RIVET - retainer 60, 62, 64 SCREW - rectifier 78
PIN - snap 28 ROD - connecting 18 SCREW - rectifier plate 76
PIN - spring 14, 18, 90 ROD - holddown 82 SCREW - regulator 58
PIN - terminal 68 ROD - mounting 84 SCREW - resistor 72
PINION - assembly 36 ROD - push 22 SCREW - retainer 30, 32, 36
PIPE - breather 14 ROTOR 80 SCREW - set 90
PIPE - fuel injection 32 SCREW - shield 88
PIPE - fuel return 32 S SCREW - shoulder 90
PIPE - oil 24 SADDLE - u-bolt 48 SCREW - shroud 50
PIPE - oil pickup 24 SCREEN - radiator 50 SCREW - solenoid 30, 36
PISTON 18, 28 SCREW 50 SCREW - starter 36
PLATE 74 SCREW - adapter 46 SCREW - strap to engine 82
PLATE - assembly 74 SCREW - angle 50 SCREW - strap to frame 82
PLATE - capacitor 74 SCREW - banjo 32 SCREW - support 14, 84
PLATE - cover 80 SCREW - base 42 SCREW - tank 52
PLATE - heat sink 76 SCREW - board 60, 64, 78 SCREW - terminal 40
PLATE - rectifier 72, 78 SCREW - box 58 SCREW - thermostat 26
PLATE - screen 14 SCREW - bracket 24, 46, 48, 50, 52, SCREW - valve adjust 14
PLATE - stop 34 56, 62, 82 SEAL 68
PLUG 6, 16, 20, 24, 26, 58, 66, 68, 72 SCREW - bracket, engine 56 SEAL - copper 32
PLUG - access hole 10 SCREW - bracket, generator 56 SEAL - lead 30
PLUG - assembly 68 SCREW - breaker 78 SEAL - oil 8, 10, 38
PLUG - drain 12 SCREW - bumper 84, 86 SEAL - valve stem 14, 16, 38
PLUG - exciter 80 SCREW - case 8, 10 SEAL - washer 24, 30
PLUG - frost 6, 14 SCREW - clamp 42, 46 SEALER - Loctite 42
PLUG - fuse 44 SCREW - clip 12, 40 SEAT - nozzle 14, 38
PLUG - pipe 6, 44, 50 SCREW - connector cover 72 SEAT - nozzle spring 34
PROTECTOR - nozzle 14, 38 SCREW - controller 64 SEAT - valve 14
PULLEY - crankshaft 18, 54 SCREW - cover 8, 14, 30, 36, 52, 58, SENSOR - oil pressure 40
PULLEY - water pump 26, 54 80 SENSOR - rpm 40, 56
PUMP 28 SCREW - diode 72, 74 SENSOR - water level 52
PUMP - fuel 28, 42 SCREW - disc to flywheel 80 SHAFT - clamp 90
PUMP - fuel injection 22, 30 SCREW - door 84 SHAFT - idler gear 22
PUMP - injection 42 SCREW - elbow 40 SHAFT - rocker arm 14
PUMP - oil 24 SCREW - exhaust manifold 20 SHAFT - water bleed 42
PUMP - water 26, 50 SCREW - fan 54, 80 SHIELD - exhaust tube 88
SCREW - field coil 36 SHIELD - muffler 88
R SCREW - flange 16 SHIELD - radiator fan 88
RADIATOR 50 SCREW - frame 56 SHIM - pulley 26
RECEPTACLE 58, 68 SCREW - gear 22 SHIM SET 34
RECEPTACLE - assembly 68 SCREW - hanger 50 SHROUD - radiator 50
RECTIFIER 72, 74, 76 SCREW - housing 10 SOCKET 72
RECTIFIER - 3 phase 78 SCREW - inlet 20 SOLENOID 36
RECTIFIER - negative 80 SCREW - intake manifold 20 SOLENOID - stop 30
RECTIFIER - positive 80 SCREW - joint 26 SPACER 26, 46, 56, 72
REGULATOR - voltage 58, 74 SCREW - latch 84 SPACER - bracket 84

INDEX - 3
 INDEX ALPHABETICAL BY DESCRIPTION

SPACER - bumper 84, 86 TRANSFORMER - current 72

SPACER - door latch 84 TUBE - exhaust 48
SPACER - fan 54, 80 TUBE - fuel feed 44
SPACER - pc board 60, 62 TUBE - sponge 16
SPACER - standoff 74
SPONGE 8 U
SPRING 14, 24, 28 U-BOLT 48
SPRING - brush 36
SPRING - nozzle 34 V
SPRING - piston 28 VALVE 28
SPRING - valve 16 VALVE - check 24, 32
SPUD - filter 42 VALVE - exhaust 14
STARTER 36 VALVE - fuel injection 32, 34
STATOR 80 VALVE - intake 14
STOPPER - pinion 36 VALVE - oil drain 12
STRAP - battery holddown 82 VALVE - Schrader 32
STRAP - ground 82 VENT 44
STRIP - bumper 86
STRIP - foam 88 W
STRIP - gasket 64 WASHER 18, 22, 30, 32
STUD - cylinder head 16 WASHER - belleville 84
STUD - exhaust manifold 20 WASHER - dome 50
STUD - fuel pump 8, 28 WASHER - insulating 40
STUD - injection pump 8, 30 WASHER - sealing 8, 24, 26, 38
STUD - nozzle retainer 14 WASHER - shoulder 60, 72, 74
STUD - power pack 56 WASHER - special 56, 90
STUD - transformer 72 WASHER - spring 90
STUD - valve cover 14 WEDGE 66, 68
SUMP - oil 12 WINDOW - bezel 64
SUPPORT - center 84
SUPPORT - frame, top shelf 84 Y
SUPPORT - right 84 YOKE - assembly 36
SUPPORT - rocker arm 14
SUPPORT - vertical, roadside 84
SWITCH - oil level 12, 40
SWITCH - oil pressure 40
SWITCH - on/off 64
SWITCH - thermo 36
SWITCH - water temperature 50

T
TAB - mounting 68, 70
TANK - expansion 52
TANK - fuel 44
TANK - overflow 50
TAPPET 22, 28
TEE - oil pressure switch 40
TEE - pipe 50
TERMINAL - pin 68
TERMINAL - socket 68
TESTER - compression 32
THERMOSTAT 26
TOOL - crimper 70
TOOL - injection pump gear remover 8
TOOL - plunger spring support plate 30
TOOL - seal installer 10
TOOL - seal remover 10
TOOL - wedge remover 70
TRANSFORMER 72

INDEX - 4